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

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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

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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

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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

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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
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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

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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

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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

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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
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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).