Sioux Tools 8000ES Operating instructions

1
FormZ655
Date 7-01/F
Page 1 of 4
Printed In U.S.A.
SERVICE INSTRUCTIONS FOR
8000ES, 8005ES, & 8050ES
Hypot Testing
Each 8000ES series tool that is serviced must be Hypot tested before being shipped back to the customer. If
you do not have this equipment, you can not service this tool.
Hypot testing is a safety test required by Underwriter’s Laboratories. It basically ensures that there are no live
metal parts exposed on the product. This condition could occur if, for instance:
1. A housing screw went through a wire;
2. A wire was stripped back too far and the bare wire contacted a bearing;
3. A wire was damaged and came into contact with a bearing.
This is a very serious safety issue so please take care to test the tool as specified below.
The tool is to be Hypot tested at 3000VAC for 1 second between:
A. Both power cord prongs and the chuck with the power switch in the ON position.
B. Between the power cord prongs and each of the three rear housing screws with the power switch in the
ONposition.
Themaximumallowablecurrentis.5mA.
Wire Routing
It is extremely important when servicing the 8000ES series tools, that wires are routed properly. Page 3 of this
instruction illustrates proper wire routing. It is very easy to pinch a wire when reassembling a tool if care is not
given to wire routing. Take note of which ribs contact the switch and brushes and where wires must be routed to
clearthem.
Grease
• The 8000ES series drills should be greased only with Kluber Klubersynth® GE14-151 (Sioux part no. 1234)
grease.
Grease is available for purchase from Sioux Tools.
We recommend 30±2 grams of grease, equally divided between the first and second stage gear reductions.
Running the grease through the gears before reassembling the tool will prolong gear life.
Motor Installation
When installing the motor assembly, take note of how the field is held in the housing. It is easy to install the field
incorrectly if unfamiliar with the tool.
There are two small tabs in the left housing half, which retain the white plastic ends of the field. The most com-
mon assembly error is to force the field in place and break off these plastic ends. Never force the field. It should
slide in easily once lined up.
Always make sure that the armature turns freely before proceeding with re-assembly.
Torque Specifications
The following torque specifications are recommended for the 8000ES series drills:

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Chuck: 40-60 in-lb
Chuck Retaining Screw: 35-45 in-lb
Strain Relief Clamp Screws: 8-12 in-lb
Switch Terminal Screws: 3-6 in-lb
Long Housing Screws (ME3L26A): 18-22 in-lb
Short Housing Screw (ME3L28): 13-17 in-lb
It is important to note that one of the housing screws is shorter than the other 8, and it also has a different
torque setting. The illustration on page 4 shows the location of the shorter screw, item #3.
When tightening the housing screws, if you do not have a tool with which you can limit the tightening torque,
they should be tightened by hand to prevent stripping. If a screw hole is stripped, the tool housing must be
replaced.
Performance Specifications
An acceptable tool is expected to perform as follows:
Service Warning Label
Any tool that requires a new housing will also require a new warning label. When a new housing set is ordered,
it will come with a service label (Sioux Tools part 68336 for 8000ES & 8050ES, part 68396 for 8005ES). The
service label is designed so that the service center can fill in the tool serial number and model number with a
pen, and then laminate it.
Copy the serial number, model number, and no-load speed off of the old label onto the new service label. Once
completed, peel the backing off of the service label lamination and laminate the label.
8000ES 8005ES 8050ES
No-LoadSpeed 1275-1425RPM 2250-2750RPM 675-900RPM
No-LoadAmpDraw < 1.7A <1.7A <1.7A
ChuckRunout .010” Max at 2” from Chuck .010” Max at 2” from Chuck .008 Max at 1.5” from Chuck

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As an aid to reassembly, take note of wire routing
and position in wire guides and traps while disman-
tling tool.
Black wire #3 is to be routed under upper brush tube and
blue wire #7.
From the switch connection, black wire #1, white wire #2
and black wire #3 are to be routed tightly over the top
surface of the switch as shown in the SWITCH DETAIL.
(Top View) below. Positioning of these wires are important
tothereassemblyofthehousinghalves.
Be sure that black field wires #3 and #5, brush assembly
red wire # 6 and brush assembly blue wire #7 are posi-
tioned deep in the bottom/side cavities of the left housing
assembly. Care must be taken to prevent contact with any
movingparts.
NOTE:
Allleads mustbe heldto ±1/8".
Allfieldleadstobemeasured
fromandperpendicularto
laminations.
Allleadlengthsarebefore
stripping.
1 Black Cord 2-3/8" Strip3/8" and tin for switch.
2 White Cord 2-3/8" Strip3/8" and tin for switch.
3 Black Field 5" Strip3/8" and tin forswitch.
4 Red Switch 2" Switch jumper. Strip both ends and tin.
5 Black Field 5" Strip3/8" and tin forswitch.
6 Red Brush 4-1/4" Componentofbrush assembly.
7 Blue Brush 2-1/2" Componentofbrush assembly.
WIRINGSPECIFICATIONS
Wire Wire Originor Length Terminals,Connectors and1 or2 EndWire Preparation
No. Color Gauge
WIRINGSCHEMATIC SWITCHDETAIL
(Top View)

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Fig. Part
No. No. Description
*OrderQuantityAsRequired
FURNISH PART, SERIAL, AND MODEL NUMBER WHEN
ORDERING PARTS
Fig. Part
No. No. Description
PrintedIn U.S.A.
SERVICE INSTRUCTIONS FOR
8000ES, 8005ES, & 8050ES
1. 68261 HousingAss'y(8000ES,8005ES)
68338 HousingAss'y(8050ES)
2. ME3L26A Screw—#8-16X.75FillisterHead(8)*
3. ME3L28 Screw—#8-16X.562FillisterHead
4. 68161 Lever
5. 68214 Armature(6Tooth)(8000ES,8005ES)
68258 Armature(4Tooth)(8050ES)
68213 Field
68159 Brush Set
6. 68079 VariableSpeedSwitch
JumperWire(Includedin Fig 5)
7. 66108 Screw—#4-20 X 5/8(2)*
8. 35587 StrainReliefClamp
9. 14167 BellCrank
10. 40079 DowelPin 1/16 X3/4
11. 68164 Switch Rod
12. 65476 BallBearing
13. 19273A HelicalGear
14. 68160 Sleeve
15. 65470 BallBearing
16. 68263 GearandPinionAss’y(8000ES,8050ES)
68397 GearandPinionAss’y(8005ES)
17. 10942 BallBearing
18. 10221 BallBearing
19. 68082 OutputShaft
20. 14165 ChuckShroud(8000ES,8005ES)
21. 21131 3/8CapacityChuck(8000ES,8005ES)
22. 57250R Screw—M5X .8X20LH(8000ES,8005ES)
23. 35798 Washer (8050ES)
24. 68229 ChuckShroud(8050ES)
25. 68187 1/2CapacityChuck(8050ES)
26. 68303 Screw—M5X8X25LH(8050ES)
27. 04291 CordProtector
28. 18549 Cord
NOTSHOWN
68336 WarningLabel
68253 Nameplate(IncludedinFig1)
30002 ChuckKey(8000ES)
30429 ChuckKey(8050ES)