Milwaukee 8960-20 Setup guide

REPAIR
INSTRUCTIONS
for Model 8960-20
No. 8960-20
8 Gallon Dust Extractor
MILWAUKEE TOOL www.milwaukeetool.com
13135 W. LISBON RD., BROOKFIELD, WI 53005
58-92-8960 042017 Drwg. 1

2
Index
A. Safety issues 4
B. Technical data 5
C. Construction / function 6
D. Troubleshooting 10
E. Service / repair 12
F. Spare parts 27
G. Electrical diagrammes 32
Construction

3
Preface
In this manual you will find
the essentials you need to
know when repairing wet and
dry cleaner 8960-20.
When carrying out repairs,
make sure you have a suitable
workbench or the like with the
necessary power supply
available.
If you determine an error in
operation, be sure to refer the
customer to the user manual.
A fault in the equipment
can have a number of causes.
Chapter D Troubleshooting
will help you here.
Use the illustrated spare
parts lists for your repairs.
These show you the location
of the individual parts and the
sequence in which they are
assembled.
Read the technical infor-
mation sheets. These will tell
you about any technical modi-
fications made after publica-
tion of this repair manual.
Technical information sheets
are a supplement to the spare
parts list until a follow-on publi-
cation.
Repair manuals and technical
information sheets should be
available at the site where re-
pairs are carried out. Further
repair manuals of the 8960-20
may be necessary for repairs
to the equipment.
It is not permitted to give the
repair manuals to third parties.
Use original MILWAUKEE
parts only!
Safety instructions marked
with this symbol in this man-
ual must be observed to
prevent danger to persons.
This symbol is used to
mark safety instructions
that must be observed to
prevent damage to the
equipment and degradation
of performance.
This symbol indicates tips
and instructions to simplify
work and to ensure safe
operation.
Symbols used to mark
instructions
A

4
Safety issues
Observe national safety
directives and regulations
for the electrical engineer-
ing trade, in particular:
IEC 60335-2-69
EN 60335-2-69
DIN VDE 105 part 1:
operation of electrical
power installations.
DIN VDE 0701/0702:
repair, modification and
testing of electrical installa-
tions.
Before starting the equip-
ment, be sure to read the
accompanying user
manual, and keep it close
as reference.
The equipment should
only be used by persons
who have been instructed
in its use and are author-
ized to do so.
Repairs should only be
made by someone who has
received proper instruc ons
for the job or who is a quali-
fed electrician.
WARNING:
The upper secon of the
machine contains live com-
ponents. Contact with live
components leads to seri-
ous or even fatal injuries.
Always disconnect the
mains plug before disassem-
bly.
For your own safety.
ESD (electrosta c discharge)
Observe the following ESD precautions before any
repair of or near electronic parts:
• Touch the protective conductor to discharge your own body.
• Possibly wear an anti-static wrist strap.
• Use a conducting floor or tabletop.
• Never touch a circuit board or electronic components - always hold them by the
plastic or insulation.
• Transport electronic parts in conductive packaging (e.g. special ESD packages).

A

5
Technical data
Possible Voltage V 110-120
Power P IECW HP 890/7,4A 1,2
Connected Load for Appliance Socket W 550/4,6A
Mains Frequency Hz 50/60
Fuse A 15
Protection Grade (moist, dust) IPX4
Protection Class (electrical) I
Maximum Airflow* l/s m³/h CFM 70 252 148
Maximum Vacuum kPa hPa in H2O23 230 92
Sound Pressure Level L PA (IEC 60335-2-69)dB(A) 69 ± 2
Working Sound Level dB(A) 60 ± 2
Vibration ISO 5349 anm/s² <2,5
Weight kg lb 14,5 31,9
Filter Surface Area m/s² 0,5
Dust Class -
Model 8960-20
B

6
Control panel
PCBA
Filter cleaning
system
Full tank sensor
Socket for power tools
Motor speed control
Rotary on/off switch
Control panel
Hatchback
Motor
unit
Buzzer
alarm
Flow
sensor
Solenoid
actuator
C
Construction

C
Construction
7
30 ltr container
Main filter element, PTFE
Floater - full tank sensor
for liquids
AntiStatic grounding clip
Container clamp
Air flow cover

8
Function
Airflow
C

9
Function
Even with extremely fine dust the automatic filter cleaning function allows you to work constantly
with the same suction performance without having to manually clean the filter.
A powerful reversed air pulse is activated every 15 seconds keeping the air flow on a high level.
The air pulse is created by a solenoid connected to a piston with double-valve. When the valve is
opened a pulse is created by difference in pressure between outside and inside of container (dirty
side of filter). The negative pressure is reduced very quickly and a reversed air pulse flows through
the filter. The dirt adhered to the filter is blown and shaken off, causing it to fall back into the tank.
Automatic filter cleaning system
Double valve system Solenoid actuator
C

10
Troubleshooting
Check:
-Mains voltage present?
- Power cord plugged into socket?
- Switch set to “I” ?
Connect switch - PCB - motor.
Is motor running?
Connect motor directly to
mains. Is motor working?
Replace motor.
Connect motor directly to
switch. Is motor running?
Yes
Yes
Yes
No
No
No
Motor not working with switch set to ”I”
Yes
Check connections and
replace switch if needed.
Check connections and
replace PCB if needed.
Check if machine is working
correctly. Calibrate flow sen-
No
Job done!! 
D

11
Check:
-Mains voltage present?
- Power cord plugged into wall socket?
- Switch set to “AUTO/TOOL” ?
- Load with > 60W plugged into socket?
Motor not working with switch set to ”AUTO/TOOL”
Yes
No
Connect switch - PCB - motor.
Is motor running?
Connect motor directly to
mains. Is motor working?
Replace motor.
Connect motor directly to
switch. Is motor running?
Yes
Yes
Yes
No
No
No
Check connections and
replace switch if needed.
Check connections and
replace PCB if needed.
Disconnect socket.
Reconnect socket. Plug
adequate load into socket.
Start load. Is motor running? No Check connections, socket and
PCB and replace if needed.
Yes
Check if machine is working
correctly. Calibrate flow sen-
sor if needed (section E.10).
Job done!! 
Troubleshooting D

12
E
1. Change motor unit 18
3. Replace rotary switch 20
4. Replace power socket 21
0. Disassembly 13
5. Change hatch back clamp 22
6. Change H-class/HEPA filter 23
8. Change solenoid 25
Service / repair
2. Change power cord 19
9. Change castor wheels 26
7. Change pressure switch 24

13
E.0
Disassembly
12
Loosen and lift the top part
of the handle with a flat-
headed screwdriver and
unscrew the lower part of
the handle (fig.1).
Unscrew the topcover
(fig.2).
TIP: Use a small flat headed
screwdriver to lift off the
WARNING: The upper section of the machine
contains live components. Contact with live
components leads to serious or even fatal
injuries.
Always disconnect the mains plug before
disassembly.
Dismount topcover and filter
TIP: Unless otherwise
stated a TX20 bit is
needed for the screws.

14
E.0
Disassembly
3Open the hatch back and
take out the filter (fig.3).
WARNING: The upper section of the
machine contains live components.
Contact with live components leads
to serious oreven fatal injuries.
Always disconnect the mains plug
before disassembly.
Disconnect and dismount Hatch back
1
Unscrew the cable relief using a
TX10 bit (fig.1).

15
E.0
Disassembly
23
Disconnect the two solenoid wires from the
grounding (fig.2) and the PCBA (fig.3).
WARNING: The upper section of the
machine contains live components.
Contact with live components leads
to serious oreven fatal injuries.
Always disconnect the mains plug
before disassembly.
Disconnect and dismount Hatch back
(continued)

16
E.0
Disassembly
4
Disconnect and dismount Hatch back
(continued)
Dismount the hatch back by pressing the hinge in
each side (fig.4).

17
E.0
Disassembly
TIP: Before disconnecting wires check if a letter
is placed in the plastic next to the connector. This
letter will refer to a letter on the PCBA and in the
electrical diagrammes.
Example:
Detail from electrical diagramme:

18
E.1
Change motor unit
1
2
Disassemble the handle, top cover, filter and hatch back as described in previous Section E.0.
Disconnect the full tank sensor wire and the motor wires from the PCBA and the switch (circles
in fig.1).
Unscrew the airguide over the motor (fig.1).
Replace the motor unit (Note: on low voltage motors the carbon brushes can be exchanged
once per motor).
Pay close attention to positioning the motor, gaskets and the wires correctly (see fig.2).
Then repeat the process backwards to assemble the machine.
Motor connection to
PCBA
Motor connection
to swicth
WARNING: The upper section of the
machine contains live components.
Contact with live components leads
to serious oreven fatal injuries.
Always disconnect the mains plug
before disassembly.
Full tank sensor
connection to PCBA
TIP: When placing the airguide into its
position put it in vertically.

19
E.2
Change power cord
4
Disassemble the handle, top cover, filter and hatch back as described in previous Section E.0.
Disconnect the wires on power cord from their connection points on switch and earth grounding
(fig.1-3).
Unscrew the cable relief (use TX10 bit) and pull the cord out of the relief hole (fig.4).
Install new power cord of same type as original.
Then repeat the process backwards to assemble the machine. Be carefull to place the cord in
the proper cable guides.
1
2
3
WARNING: The upper section of the
machine contains live components.
Contact with live components leads
to serious oreven fatal injuries.
Always disconnect the mains plug
before disassembly.

20
E.3
Replace rotary switch
12
Disassemble the handle and top cover as described in previous Section E.0.
Take off control panel and disconnect the wires on the switch (fig.1).
Unscrew the rotary knob and dismount the rotary switch (fig.2).
Then repeat the process backwards to assemble the machine.
WARNING: The upper section of the
machine contains live components.
Contact with live components leads
to serious oreven fatal injuries.
Always disconnect the mains plug
before disassembly.