Milwaukee K900K User manual

1
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
1
Remove the handle (1) by turning it
counter-clockwise.
Disassembling
the handle
1 Unscrew the knob (3) and remove the
screw (1).
2
Press the spring ring (2) in direction of the
arrow and remove the handle (4).
1
1
1
34
2
2

2
PAGE
4939 5258 01
Removing the
spring ring
1
Remove both retainers (1).
2 Slightly spread the spring ring (2) and pull
it off the machine towards the front.
Removing the
tool acceptance
1
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!
2
Remove the seal ring (3) with circlip pliers
from the gear box (2).
Disassembling
the tool
acceptance
1
Expel res. press off the latch bar (7)
and remove the following parts:
– latch (4)
– spring (5)
– sleeve (6).
2
Lever off the seal ring (3) and the
O-ring (2) from the tool acceptance (1)
with a screwdriver.
Disassembling
the gear cover
1
Remove six screws (1) with washers from
the gear cover (2).
2
Remove the felt (4) from the gear cover.
3
Remove the gasket (3) from the groove of
the gear cover (5).
1
1
2
3
4
3
2
1
4
1 2 3
4 5 6 7
5
3
4
1
2
5
6

3
PAGE
4939 5258 01
Combined
drill/chisel
hammer:
Removing
the spindle
1
Expel the complete spindle assembly with
light taps on the rear spindle end (1) with
a plastic hammer.
Chisel
hammer:
Removing
the spindle
1
Loosen the seal ring (3) with circlip pliers
from the spindle groove.
2
Expel the complete spindle assembly with
light taps on the rear spindle end (4) with
a plastic hammer.
3
Remove the seal ring (3), the attach-
ment ring (2) and the O-ring (1) from the
gear box.
1
7
321
4
7

4
PAGE
4939 5258 01
Disassembling
the spindle
1
Remove the thrust collar (1) from the
spindle (7). Remove the O-ring (2) from
the thrust collar (1).
2
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)!
3
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.
1
Remove the following parts from the
spindle (C):
– ball race (1)
– disc (2)
– damping ring (3)
– attachment ring (4).
2
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.
3 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).
4
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).
5
Remove the thrust collar (9) and the back-
pressure ring (A) from the spindle (C).
1 2 3
4
56
7
5
8
12
34
567
8
C
B
A
9
C
5
9

5
PAGE
4939 5258 01
Disassembling
the spindle
1
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
8 mm
36 mm
39 mm
oder
90°1.
2.
90°1.
2.
1
4
6
5
3
7
8
2
or
10

6
PAGE
4939 5258 01
Removing the
piston assembly
1
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).
2 Combined drill/chisel hammer:
Additionally remove the spindle bevel
gear (1).
Dismantling the
motor housing
1
Remove the two screws (1) from the
service cover (2) and pull out the service
cover (2) in direction of arrow.
2
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.
3
Remove four Allen screws (4) from the
motor housing.
4 Pull the gear box (5) with the armature
from the motor housing.
123
11
5
3
4
12
4
12

7
PAGE
4939 5258 01
Disassembling
the armature
1
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).
2
Remove the seal (2) from the gear box (1).
3
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).
4
Remove the locking ring (5) from the
bearing end plate (7) and press out the
bearing (6).
5
Separate the fan (9) from the armature (B)
with the forcing discs (A).
6
Remove the rubber sleeve (D) and press
off the bearing (C).
Detaching the
crank wheel
1
Remove the following parts from the gear
box (4):
–crank wheel (5)
–disc (8)
–axial bearing (9)
–disc (B).
2
Pull the needle bearings (6) and (7) with
the interior extractor (A) from the crank
wheel (5).
3
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)!
9
23456
8
7
A
B
C
D
1
13
1
2
3
4
5
6
7
9
B
A
8
14

8
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).
12
15
34
5
6
D
8
9
A
BC
E
7
1
2
16

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.
12
3
4
56
7
8
17

10
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
A
B
35 g B
10 g B
2 g B
A
10 g B
2 g B
AA
B
AA
daub
thinly
daub
thinly
daub
thinly
daub
thinly
daub
thinly
daub
thinly
1 g A
1 g A
approx.
48 g A
1 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).

11
PAGE
4939 5258 01
Lubrication: Combined drill/chisel hammer
Put approx. 48 g of Darina
grease (A) into the spindle
housing (gear box from the front)
Fill 35 g grease Urethyn (B) into the
spindle (the percussion body takes
up some grease)
Apply 80 g grease Darina (A)
to the safety clutch
Apply 20 g of Darina
grease (A) to the crank wheel

12
PAGE
4939 5258 01
Lubrication: Chisel hammer
Put approx. 48 g of Darina
grease (A) into the spindle
housing (gear box from the front)
Put 120 g of Darina grease (A)
into the gear box
Put 20 g of Darina grease (A)
to the crank wheel
Fill 35 g grease Urethyn (B) into the
spindle (the percussion body takes
up some grease)

13
PAGE
4939 5258 01
Sequence and torques of the screws:
Torques Bearing cover 4 Nm A 1)
Top gear cover 4.5 Nm B 1)
Gear cover 3 Nm C
Chisel acceptance 18 Nm D 1)
Motor housing 13 Nm E 1)
Service cover 1.3 Nm F
Handle 3 Nm G
Field 2 Nm H
Anti-vibration mechanism 3 Nm I
Round nut 16 Nm J
Cable clip 1.3 Nm K
Carbon brush holders 1.3 Nm L
Connection wires switch 0.5 Nm M
Secured washer 4 Nm N
1) Additionally secure the screws with a screw locking agent using an Omnifit 80 or Loctite 222.
1
2
3
4
5
7
6
6
2
4
5
1
7
3
BA
C
D
E
F
G
H
I
J
K
L
M
N

14
PAGE
4939 5258 01
Assembly
Mounting the
anti-vibration
mechanism
and the field
1Insert the field (6) into the motor hous-
ing (8) and fix it with two screws (7)
(torque = 2 Nm).
2Insert the following parts of the anti-
vibration mechanism into the motor
housing (8):
–transition piece (3)
–spring (2)
–thrust piece (1).
3Fix the anti-vibration mechanism with the
screw (4) (torque = 3 Nm).
4Insert the air deflector ring (5) into the
motor housing (8). Mind the right position!
Assembling
the electronic
component
1Mount the following parts:
–secured washer (9)
–four screws (8)
(torque = 4 Nm)
–electronic part (E)
–two carbon brush holders (B)
☞Insert the end of the flat spiral
spring (G) into the slot (H) in the pin of
the carbon brush holder as indicated in
the enlargement of the figure (mean-
ing: hook the flat spiral spring (G) into
the pin in the “11 o’clock”position!).
Tension the flat spiral spring by 1 turn
in clockwise direction.
Afterwards position the other spring
end (I) onto the carbon brush holder
(“ready position”).
–two screws (A)
(torque = 1.3 Nm)
–two wires (D)
–four O-rings (C).
☞Take care that no wires are jammed or
squeezed.
☞All wires must be correctly inserted
between the cable entry lugs
(see pictures on page 15).
2Insert the switch (3) into the handle
half (F).
3Insert the mains cable (7) and fix the
strain relief (6) with the screw (5)
(torque = 1.3 Nm).
4Connect the mains cable (7) with the
switch (3) and with two screws (4)
(torque = 0.5 Nm).
5Mount the handle half (2) and fix the han-
dle with four screws (1) (torque = 3 Nm).
f
d
e
c
123
4
5 6 7
8
1
b
a
f
a
c
b
d
h
e
34
56
D
8
9
A
BC
E
7
1
2
F
G
H
I
2

15
PAGE
4939 5258 01
white:
carbon brush holder –
carbon brush
brown:
carbon brush –electronic
(carbon brush cutoff)
blue:
field –electronic
red:
field –carbon brush holder
red:
field –electronic
red:
field –carbon brush
holder
white:
carbon brush holder –
carbon brush
Wiring in the
machine
black:
electronic –switch
Wiring in the handle
brown:
mains cable to switch
black:
switch –electronic blue:
mains cable to switch

16
PAGE
4939 5258 01
Mounting the
gear cover 1Fix the gear cover (2) with two screws (1) onto the gear box (torque = 3 Nm).
Mounting the
crank wheel 1Combined drill/chisel hammer: Press the needle bearings (2) and (3) flush into
the gear box (4).
☞The names on the needle bearings
must be visible!
2Press the needle bearings (6) and (7)
flush into the crank wheel (5).
☞The names on the needle bearings
must be visible!
3Insert the safety clutch (1) into the gear
box (4).
☞The safety cluth is pre-set and is
released at:
34 Nm static
120 Nm dynamic.
☞The safety clutch is only available as a
complete assembly!
4Insert the following parts into the gear box:
–disc (8)
–axial bearing (9)
–disc (A)
–crank wheel assembly (5).
Mode of
operation of the
safety clutch
If the rotational movement of the drill is
blocked, the safety clutch protects the user
from the rotation of the machine. The safety
clutch limits the maximum torque of the drill-
ing tool. As soon as this limit is exceeded, the
rollers in the safety clutch withdraw, and the
toothed gear of the clutch can rotate, where-
as at the same time the bevel wheel and the
clutch wheel are idle. This is due to the fact
that the cam track applies greater force on the
rollers than the spring. The driving mecha-
nism from motor to drilling tool is interrupted.
12
3
1
2
3
4
5
6
8
9
A
7
4
Nockenlaufbahn
Kraft durch
Nocke
Federkraft
Kupplungszahnrad
dreht weiter
Kegelrad u. Kupplungs-
rad sind blockiert
Walzen
weichen
zurück
Walze
Bevel wheel and
clutch wheel are idle Roller
Power
by cam
Cam track
Toothed gear
of the
clutch keeps
rotating
Rollers
withdraw
Resilience

17
PAGE
4939 5258 01
Assembling
the armature 1Press on the bearing (B) and put on the rubber sleeve (C).
2See illustration below:
Press the fan (9) onto the indicated bear-
ing measure. Afterwards, apply some in-
stant glue (e. g. Sicomet) on the armature
shaft (marked with arrows).
☞The distance between the upper side
of the fan (9) and the lower side of the
bearing (B) must be 159 mm (bearing
measure) according to the below illus-
tration.
3Press the bearing (6) into the bearing end
plate (7) and insert the locking ring (5).
4Put the bearing end plate assembly (7) on
the armature.
5Screw in the seal ring (4) with the
pin-type face spanner (service tool) (3)
(torque = 16 Nm).
6Insert the seal (2) into the gear box (1).
7Apply locking agent to the three
screws (8).
Insert the bearing end plate with the
armature (A) into the gear box (1) and
fix them with the three screws (8)
(torque = 4 Nm).
9
2345
6
8
7
A
BC
1
5
Bearing measure: 159 mm
9B
Instant glue
Instant glue
(e. g. Sicomet)
(e. g. Sicomet)

18
PAGE
4939 5258 01
Mounting the
motor housing
1
Apply locking agent on the four screws (4).
Insert the gear box with the armature (5)
into the motor housing (6) and fix them
with the four screws (4) cross-wise
(torque = 13 Nm).
2
Insert the carbon brushes (3) on both
sides and connect them.
3
Insert the service cover (1) slanted and fix
it with two screws (2) (torque = 1.3 Nm).
Checking the
Clearance of
the Gear (up to
manufacturing
date C2004)
1
Determine the gear clearance between
the armature pinion and the crank wheel:
1. Position the depth gauge (A) onto the
crank wheel (B) and determine the
measuring value M
1.
.
2. Pull up the crank wheel (B) by hand.
Position the depth gauge (A) onto the
crank wheel (B) and determine
the measuring value M
2.
.
3. Calculate the difference : M
1.
– M
2.
– Difference between 0.1 mm and
0.44 mm: O.K.
– Difference < 0.1 mm:
Replace two discs (see page 16,
step 4, discs (8) and (A)) with two
discs 4931 375 785 (2x0.92 mm).
– Difference > 0,44 mm:
Insert additional compensating
discs under disc (A)
(see page 16, step 4):
5
3
4
2
1
6
6
No. Compensating disc Thickness
[mm]
9170 0223 40 0.10
9170 0223 50 0.15
9170 0223 60 0.20
9170 0220 70 0.23
9170 0220 80 0.30
9170 0220 90 0.38
9170 0221 10 0.51
1. M1.
= ?
2. M2.
= ?
3. Differenz = M1.–M2.
–Differenz <0,1 mm
2.
(4931 375 785)
–Differenz
0,1mm bis 0, 44 mm
⇒ 2 x 0,92 mm
–Differenz >0,44 mm
⇒ Ausgleichscheiben
⇒ OK
A
B
Difference = M
1.
–M
2.
Difference
0.1 mm up to 0.44 mm
Difference < 0.1 mm
Difference > 0.44 mm
Compensating discs
.
7

19
PAGE
4939 5258 01
Mounting
the piston
1
Combined drill/chisel hammer:
Insert the spindle bevel gear (1) into the
gear box.
2
Mount the O-ring (2) on the piston (3).
Put the piston (3) on the tappet of the
crank wheel (4).
3
Insert the piston into the spindle bevel
gear (1).
123
4
8

20
PAGE
4939 5258 01
Assembling
the spindle
1
Machines with a date of manufacture
up to 06/2004: Insert the cross bracket (1)
(width 7 mm) into the spindle openings (2)
turn it 90°.
☞
The smooth side of the cross brack-
et (1) (illustrated dark ) must face
the front towards the tool acceptance,
in mounted condition!
The curve ot fhe cross bracket must fit
into the curve of the spindle (2)!
When ordering the cross bracket, the
reversion kit No. 4931 375 788 is deliv-
ered :
Spindle opening = 36 mm:
Insert the chromium plated cross brack-
et (3) (width 8 mm) into the spindle (4)
from the front.
Spindle opening = 39 mm:
Insert the chromium platet cross brack-
et (5) (width 8 mm) into the spindle open-
ings (6) and turn it 90°.
Machines with a date of manufacture
from 07/2004: Insert the ring (7) (black)
into the spindle (8) from the front.
Please note when exchanging the spin-
dle sleeve:
☞
When the old spindle sleeve (up to
DoM 06/2004) is exchanged for the
new spindle sleeve (8) (4931 375 803
(drill/chisel hammer), 4931 375 802
(chisel hammer)), it is imperative that
the new percussion body (9)
(4931 375 782) is used! Otherwise the
spindle is destroyed when in operation.
☞
When the new spindle and the new
percussion body are inserted, the rat-
ing plate of the machine must also be
replaced (4931 375 809: new rating
plate for drill/chisel hammer;
4931 375 819: new rating plate for
chisel hammer)!
5 mm
8 mm
Exchanging the
spindle sleeve
06/2004
07/2004
7 mm
8 mm
8 mm
36 mm
39 mm
oder
36 mm
39 mm
+
4931 375 782
90°
1.
2.
1.
2.
90°
1
2
6
5
3
79
4
8
or
9