2 - Milwaukee Electric Tool

REPAIR
INSTRUCTIONS
Cat. No. 5337-20
3/4” Hex Demolition Hammer
Cat. No. 5340-20
2” Spline Rotary Hammer
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 W. LISBON ROAD • BROOKFIELD, WISCONSIN 53005-2550
58-92-5300 d3
032005
PAGE
REPAIR
INSTRUCTIONS
SpecialTools
Require
–
–
–
–
–
58-92-5300 d3
Forcing discs
Hex key 4 mm
Hex key 5 mm
Sleeve
Pin-type face spanner
–
61-10-0011
61-10-0011
61-10-0013
61-10-0012
61-10-0012
61-10-0013
Disassembly
Removing the
auxiliary handle
1 Remove handle (1) by turning it counter-
Disassembling
the handle
1 Unscrew knob (3) and remove screw (1).
2 Press spring ring (2) in direction of arrows
clockwise.
1
1
and remove handle (4).
2
3 4
2
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REPAIR
INSTRUCTIONS
Removing the
spring ring
58-92-5300 d3
1 Remove both retainers (1).
2 Slightly spread spring ring (2) and pull it off
1
the machine towards the front.
2
1
Removing the
nose piece assembly
1 Remove four screws (4) with an 6mm hex
key and remove nose piece assembly (1)
1
2
2 Remove retaining ring (3) from gear box
(2).
3
4
Disassembling
the nose piece
assembly
1 Drive/press out latch bar (7) and remove
the following parts:
– latch (4)
– spring (5)
– sleeve (6).
1
2
3
2 Pry off seal ring (3) and the O-ring (2) from
nose piece (1) with a screwdriver.
☞
Drive out nose piece latch bar with 3/8”
(10mm) piece of round bar stock.
4 5 6
Disassembling
the gear box cover
1 Remove six 4mm hex screws (1) with
washers from gear box cover (2).
2 Remove felt (4) from gear box cover.
3 Remove gasket (3) from groove of the
1
2
gear box (5).
3
4
5
7
3
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REPAIR
INSTRUCTIONS
Combined
drill/chisel
hammer:
Removing
the spindle
Chisel
hammer:
58-92-5300 d3
1 Drive out the complete spindle assembly
with light taps on rear spindle spline end
(1) with a plastic face hammer.
☞
1
Tap spline area of spindle assembly, do
not strike piston assembly.
1 Remove retaining ring (3) with retaining
ring pliers from the spindle groove.
1 2
3
2 Drive out the complete spindle assembly
Removing
the spindle
with light taps on the rear spindle end (4)
with a plastic face hammer.
3 Remove retaining ring (3), washer (2) and
O-ring (1) from gear box.
☞
Tap spline area of spindle assembly,
donot strike piston assembly.
4
4
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REPAIR
INSTRUCTIONS
Disassembling
the spindle
58-92-5300 d3
1 Remove thrust collar (1) from spindle (7).
Remove O-ring (2) from thrust collar (1).
2 Drive out ram (5) from spindle (7) by tapping it lightly with a plastic face hammer.
Remove O-ring (6) from ram body (5).
3 Remove retaining ring (3) from spindle (7).
4
1
2 3
5
7
Disassembling
the spindle
1 Remove following parts from spindle (A):
–
–
–
–
2
roller race (1)
washer (.154 thick) (2)
spindle sleeve o-ring (3)
attachment washer (.118 thick) (4).
1
8
2 Remove four rollers (B) with a magnetic
screwdriver from spindle (A).
☞
Should rollers (B) be stuck, tap around
them with light blows with a plastic face
hammer to help expel them.
3 Combined drill/chisel hammer: pull
striker guide (5) (with hexagon socket)
from spindle (A).
Chisel hammer: remove striker guide (5)
(without hexagon socket) from spindle (A).
6
7
5
4
3
4 Remove the following parts from striker
guide (5):
– striker (7)
– O-ring (6).
Remove three O-rings (8) from striker (7).
A
5 Remove thrust collar (9), back pressure oring (10) and thrust washer (11) from spindle (A).
9 10 11
B
6
5
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REPAIR
INSTRUCTIONS
Removing the
piston assembly
58-92-5300 d3
1 Bring piston (3) into the upper dead center
3
position and remove it from gear. Remove
O-ring (2) from piston (3).
2
1
2 Combined drill/chisel hammer:
Additionally remove spindle bevel gear
(1).
Disassembling
the motor housing
1 Remove two screws (1) from service cover
(2) and pull out service cover (2) in direction of arrow.
2 Lift springs (3) on both sides of carbon
brush cover and pull carbon brush out (4).
Remove carbon brush lead.
4
1
2
3 Remove four hex head screws (5) from the
motor housing.
3
4 Remove air deflecting ring (7) from motor
housing.
5 Pull gear box (6) with armature from motor
housing.
☞
Note: Carbon brush set consists of two
brushes, one brush has a secondary
lead incorporated into it. This lead must
be disconnected from the electronic
module at this time.
4
7
5
6
6
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REPAIR
INSTRUCTIONS
Disassembling
the armature
58-92-5300 d3
1 Remove three hex head screws (8) from
bearing end plate (7) and pull complete armature assembly (B) with bearing end
plate (7) from gear box (1).
2 Remove o-ring (2) from gear box (1).
3 Insert pin-type face spanner (service tool
7
6
61-10-0012) (3) into seal nut (4) and remove seal nut (4) counter-clockwise.
Remove bearing end plate (7) from armature assembly.
4 Remove retaining ring (5) from bearing
end plate (7) and press out bearing (6).
8
5
3
4
2
1
5 Separate fan (9) from armature (B) with
forcing discs (A).
6 Remove bearing cup (D) and press off
bearing (C).
☞
If armature fan requires removal, use
service fixture 61-10-0011 as illustrated, (follow fan reassembly procedure).
D
C
B
A
9
Removing the
crank wheel
1 Remove following parts from gear box (8):
–
–
–
–
crank wheel (1)
thrust washer (2)
thrust bearing (3)
thrust washer (4).
1
2 Combined drill/chisel hammer:
Additionally remove clutch (5) from gear
box (8). Remove needle bearings (6) and
(7) from gear box (8).
5
The chisel hammer does not have a
clutch (5) and needle bearings (6) and
(7)!
6
☞
☞
☞
Needle bearings (6) and (7) are caged
bearings. To remove, just lift out of
gear box. Care should be taken not to
damage bearings when servicing the
machine.
Do not wash clutch gear assembly (5).
(Wipe off with a clean dry rag ONLY).
7
8
2
3
4
7
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REPAIR
INSTRUCTIONS
Removing the
gear cover
58-92-5300 d3
1 Remove two screws (1) and remove gear
cover (2).
☞
The exposed plane surface serves only
for manufacturing the gear box and has
no other function!
2
1
Disassembling
the electronic
component
1 Remove four screws (1) from handle and
1
remove handle half (2).
4
3
2
2 To remove cord leads, remove two screws
(4) from the switch.
3 Remove screws (5) from cord clamp (6)
and remove cord (7).
4 Remove the following parts:
–
–
–
–
–
–
–
four O-rings (C)
two wires (D)
two screws (A)
two carbon brush holders (B)
electronic part (E)
four screws (8)
side handle plate (9)
5
6
7
8
A
9
B
C
D
E
8
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REPAIR
INSTRUCTIONS
Removing the
anti-vibration
mechanism
and the field
58-92-5300 d3
1 Remove air deflector ring (5).
2 Remove screw (4). Remove the following
3
parts of the anti-vibration mechanism from
motor housing (8):
– vibration spring cover (1)
– spring (2)
– vibration lever (3).
☞
Caution: Screw (4) and vibration
spring cover (1) are under spring pressure.
2
1
4
3 Remove two screws (7) and remove field
(6) from motor housing (8).
☞
8
Should the field be stuck, tap the motor
housing (8) lightly with a plastic face
hammer.
7
6
5
9
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REPAIR
INSTRUCTIONS
58-92-5300 d3
10
Maintenance
General
It is recommended that maintenance be performed on the machine at regular intervals or when the carbon brushes reach end of life.
Cleaning
Clean all parts – with the exception of the electrical parts and clutch with cold cleaning agent. Caution!
No cleaning agent should penetrate into the bearing. Clean the electrical parts with a dry brush.
Check for wear
Check disassembled parts for wear (visual inspection) and replace worn parts.
Electrical tests
Before reassembling, perform an electrical test on all relevant parts. Refer to the electrical instructions
in the Repair Instructions-General Notes, No. 58-92-0001.
Lubrication
Each time maintenance is performed, the machine is to be lubricated as stated in the lubrication notes.
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 notes.
Refer to the current service parts list for all components in service maintenance kit.
Maintenance Kit No. 14-46-0041 contains three (3) different greases:
Type ‘P’ grease (2 - 100g tubes)
Type ‘L’ bit grease (1 - 20g tube)
Type ‘Q’ grease (1 - 45g tube)
OR
Type ‘P’ grease (2 - 100g tubes)
Type ‘L’ bit grease (1 - 20g tube)
Type ‘Q2’ grease (1 - 45g tube)
Check your maintenance kit and determine if there is ‘Q’ or Q2” grease and follow the instructions for the
tool that you have located on pages 11 and 12.
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REPAIR
INSTRUCTIONS
58-92-5300 d3
11
Lubrication: Combined drill/chisel hammer (5340-20)
Re
PAGE
REPAIR
INSTRUCTIONS
Lubrication: Chisel hammer (5337-20)
58-92-5300 d3
12
PAGE
REPAIR
INSTRUCTIONS
58-92-5300 d3
13
Sequence and torques of the screws:
B
A
J
G
M
D
N
C
K
F
L
E
I
H
PAGE
REPAIR
INSTRUCTIONS
58-92-5300 d3
Assembly
Installing the
anti-vibration
mechanism
and field
1 Install field (6) into motor housing (8) and
3
secure it with two screws (7) (torque = 2
Nm / 18 in. lbs.).
2
1
2 Install the following parts of anti-vibration
mechanism into motor housing (8):
– vibration lever (3)
– spring (2)
– vibration spring cover (1).
3 Tighten anti-vibration mechanism with
4
8
screw (4) (torque = 3 Nm / 27 in. lbs.).
4 Install air deflector ring (5) into motor
housing (8). Mind the right position!
5 6
Assembling
the electronic
component
1 Install the following parts:
1
– side handle plate (9)
– side handle screws (8)
(torque = 4 Nm / 35 in. lbs.)
– dial switch (E)
– two carbon brush holders (B)
☞
2
Insert end of flat spiral spring (G) into
slot (H) in pin of carbon brush holder as
indicated in the enlargement of the figure (meaning: hook flat spiral spring
(G) into pin in the “11 o’clock” position!). Tension flat spiral spring by 1
turn in a clockwise direction. Afterwards position other spring end (I) onto
carbon brush holder (“ready position”).
5
6
I
G
H
Take care that no wires are jammed or
pinched.
F
7
8
A
All wires must be correctly installed
between the cable entry lugs (refer to
wiring instructions).
2 Install switch (3) into handle half (F).
3 Install cord (7) and secure cord clamp (6)
4
3
– two switch screws (4)
(torque = 0.5 Nm / 4 in. lbs.)
– two wires (D)
– four O-rings (C).
☞
☞
7
9
B
C
with screws (5) (torque = 1.3 Nm / 12 in.
lbs.).
4 Connect cord leads (7) to switch (3) and
secure screws (4) (torque = 0.5 Nm / 4 in.
lbs.).
D
5 Install handle half (2) and secure handle
half with four screws (1) (torque = 3 Nm /
27 in. lbs.).
E
14
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REPAIR
INSTRUCTIONS
Installing the
gear box cover
58-92-5300 d3
1 Secure gear box cover (2) with two screws
(1) onto the gear box (torque = 3 Nm / 27
in. lbs.).
1
Combined
drill/chisel
hammer:
2
1 Combined drill/chisel hammer: Place
caged needle bearings (1) into lubricated
steel sleeve in gear box (2).
7
2 Install clutch assembly (3) into gear box
Installing the
clutch and crank
assembly
(2) in direction of arrow.
3 Install the following pre-lubricated parts
over stationary axle inside gear box (2).
– thrust washer (4)
– thrust bearing (5)
– thrust washer (6)
4 Install crank wheel assembly (7) over gear
box axle assembly.
☞
Chisel hammer:
Installing the
crank assembly
The static slip of the clutch is pre-set. If
the rotational movement of the bit is
blocked, the clutch protects the rotary
hammer.The clutch limits the maximum torque of the tool. See instructions for checking the static slip of the
clutch.
3
1
1
6
5
4
2
1 Install the following pre-lubricated parts
over stationary axle inside gear box (1).
– thrust washer (2)
– thrust bearing (3)
– thrust washer (4)
5
2 Install crank wheel assembly (5) over gear
box axle assembly.
4
3
2
1
15
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REPAIR
INSTRUCTIONS
Assembling the
armature
58-92-5300 d3
1 Press bearing (B) onto armature shaft and
install bearing cup (C) into rear bearing
bore of motor housing (not shown).
2 See illustration below:
☞
Refer to chart”A” below when removing
or installing the armature fan. It is very
important to press armature fan to dimension shown, then apply Loctite ®
401 Porous Material Bonding Adhesive
around the entire base of fan (360°).
Allow the bonding agent to cure completely per manufacturers instructions.
6
4
3
7
8
5
2
1
3 Press bearing (6) into bearing end plate
(7) and install locking ring (5).
4 Install bearing end plate assembly (7) onto
the armature shaft.
5 Screw in the seal nut (4) with the
pin-type face spanner (3) [61-10-0012]
(torque = 16 Nm / 141 in. lbs.).
6 Install o-ring (2) into gear box (1).
7 Apply Blue Loctite® to the three screws
(8).
Install bearing end plate with armature
assembly (A) into rear bearing bore in
gear box (1) and tighten the three screws
(8) (torque = 4 Nm / 35 in. lbs.).
B
A
9
C
16
PAGE
REPAIR
INSTRUCTIONS
Installing the
motor housing
58-92-5300 d3
1 Apply Blue loctite® onto four screws (4).
Install gear box and armature (5) into motor housing (6) and tighten the four screws
(4) cross-wise (torque = 13 Nm / 115 in.
lbs.).
1
2
2 Install and connect carbon brushes (3) on
both sides (refer to wiring instruction bulletin).
6
3 Install service cover (1) and secure it with
two screws (2) (torque = 1.3 Nm / 12 in.
lbs.).
☞
☞
3
Slant service lid (1) slightly when installing and tighten screws (torque =
1.3 Nm / 12 in. lbs.).
Note: Carbon brush set consists of two
brushes, one brush has a secondary
lead incorporated into it. This lead
must be connected to the electronic
module at this time.
4
5
Installing
the piston
1 Combined drill/chisel hammer:
Install spindle bevel gear (1) into gear box
(5).
2
1
2 Install O-ring (2) onto piston (3).
3 Install piston assembly (3) over crankwheel pin (4).
☞
Refer to lubrication chart for type and
amount of lubrication for hammer being serviced.
5
4
3
17
PAGE
REPAIR
INSTRUCTIONS
Assembling
the spindle
58-92-5300 d3
1 Install washer (E) and the back pressure
2
o-ring (C) into spindle (F).
☞
Install thrust collar (B) in the right position: the chamfer of thrust collar (B)
must face striker (8).
3
1
9
8
2 Install three o-rings (9) onto striker (8).
3 Combined drill/chisel hammer:
Install o-ring (7) onto striker guide (6).
Insert striker (8) into striker guide (6) (with
hex socket, 1 outer ring).
Chisel hammer:
Install o-ring (7)onto the striker guide (A).
Install striker (8) into striker guide (A)
(without hex socket, 2 outer rings).
☞
7
6
5
4
A
The striker (8) must protrude past the
striker guide (6) approx. 0.5 mm! Refer
to illustration below. (Strike guide (6)
can be identified by the hexagon socket and has only one outer ring. Striker
guide (A) can be identified with the two
outer rings and has no hexagon socket.)
E
F
4 Install striker guide assembly 6,7,8,9 or
A,7,8,9 into spindle (F) facing thrust collar
(B).
5 Install four rollers (D) into spindle (F).
6 Install the following parts onto spindle (F):
–
–
–
–
–
attachment washer (5),.118 thick
o-ring (4)
washer (3),.154 thick
roller race (2)
retaining ring (1).
B C
8
D
6
8
A
6
8
Assembling ram
into the spindle
1 Install o-ring (3) onto ram (2). Lubricate
2
ram prior to assembly.
2 Install ram (2) into spindle (1).
☞
Lubricate front of gear box per lubrication chart specifications prior to installing spindle assembly.
1
3
18
PAGE
REPAIR
INSTRUCTIONS
SDS Max
combined
drill/chisel
hammer:
1 Secure hammer gear box in a machinists
vise.
2 Install service fixture #61-10-2060 into
front spindle.
3 Engage / lock external splines of set collar
To check static
slip of clutch
into internal splines of spindle bevel gear
(figs. 2 and 3).
4 Install a piece of nylon bar stock or equivalent material, approximately 3/4” x 1-1/8”
in between locking plate and gear box.
Turn service fixture slowly clockwise until
nylon bar stock is wedged tight between
wall of gear box and crank wheel, as
shown (fig. 3). Once crank wheel has been
secured, continue to turn torque wrench in
a clockwise direction until clutch slips.
5 Clutch must slip at 96-140 ft. lbs. (130-190
Nm.) at spindle, checked clockwise as
viewed from the front of the tool. (Refer to
note below).
Note: If the static slip of the clutch doesn’t
fall between the listings, do the following:
Run the tool at the highest speed (“G” on the
dial switch) for 10 minutes. Immediately remove gear box cover and insert recommended nylon / plastic block into gear box to
prevent gears from rotating. Turn the torque
wrench clockwise and slip the clutch 8 times
before actual slip torque readings are taken.
Take an additional 8 slip torque readings and
determine the average of the 8 readings. The
average should be within the torque range
specified.
Spline hammer:
1 Install service fixture #61-10-2065 into
front spindle.
2 Install a piece of nylon bar stock or equivTo check static
slip of clutch
alent material, approximately 3/4” x 1-1/8”
into gear box on the opposite side of piston connecting rod. Turn service fixture
slowly clockwise until nylon bar stock is
wedged tight between wall of gear box
and crank wheel, as shown (fig. 1). Once
crank wheel has been secured, continue
to turn torque wrench in a clockwise direction until clutch slips.
3 Clutch must slip at 96-140 ft. lbs. (130190 Nm.) at spindle, checked clockwise
as viewed from the front of the tool. (Refer
to note above).
58-92-5300 d3
19
PAGE
REPAIR
INSTRUCTIONS
Combined
drill/chisel
hammer:
Installing the
spindle
58-92-5300 d3
1 Install complete spindle assembly (1) into
gear box (2) as far as it will go, aligning external splines on spindle (1) with internal
splines of previously installed spindle bevel gear.
☞
☞
Piston assembly (3) must enter the
rear/end of spindle (1)!
Spindle (1) gets the necessary
lubrication when it is inserted into gear
box (2).
2
1
3
Chisel
hammer:
Installing the
spindle
1 To prepare, place o-ring (1), attachment
ring (2) and locking ring (3) into gear box
(5).
3
2 Install complete spindle assembly (4) into
gear box (5) and lead it through o-ring (1),
attachment ring (2) and locking ring (3).
☞
1
2
Spindle (4) gets the necessary
lubrication when it is inserted into gear
box (5).
3 Insert spindle (4) as far as it will go.
☞
Piston (6) must enter the rear/end of
spindle!
5
4 Install retaining ring (3) completely into
spindle groove.
☞
☞
The retaining ring (3) must audibly
engage into the spindle groove!
Retaining ring (3) must be spread
slightly when installing spindle assembly.
4
6
20
PAGE
REPAIR
INSTRUCTIONS
Installing the
top gear box cover
58-92-5300 d3
1 Install gasket (4) into gear box (6). Mind
the right position!
☞
Gasket (4) is pre-formed and fits the
groove of gear box (6) exactly!
Lower side
of the gear
box cover
5
1
4
2
4
2 Place felt (5) into the top gear box cover
(3). Mind the right position! It serves to
vent the gear box!
☞
The felt (5) must be placed in relief (1)
of the lower part of the gear box cover
(3)! See illustration.
3 Install six screws with washers (2) into
gear box cover (3) and tighten. (torque =
4.5 Nm / 40 in. lbs.).
☞
Installing the
thrust collar
The six screws must be tightened
according to indicated numbers (1 – 7)
in ascending sequence! Push the cover (3) slightly in direction of arrow!
1 Install o-ring (1) onto thrust collar (2).
2 Position thrust collar assembly (1,2) into
gear box (3) until the outside face of the
thrust collar assembly is flush with the
face of the gear box. Place the open end
of service fixture (4), 61-10-0013, over the
spindle assembly and gently push the
thrust collar into the gear box.
☞
The internal retaining ring groove must
be visible after thrust ring (2) has been
installed, if it is not, the spindle assembly may have been assembled incorrectly or is in a bind.
3
4
5
6
21
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REPAIR
INSTRUCTIONS
Installing the
nose piece assembly
58-92-5300 d3
1 Install o-ring (2) and seal ring (3) into the
1
nose piece assembly (1).
☞
☞
2
3
Install seal ring (3) into the right
position: The sealing lips must face the
outside!
Seal ring (3) must be pressed flush to
nose piece (1), otherwise it will wear
very quickly!
2 Install latch bar (7) into nose piece (1) and
insert the sleeve (6) and the spring (5) on
the other side.
3 Install latch assembly (4).
7
4 5 6
3
Installing the
nose piece assembly
1 Apply Blue Loctite® Threadlocker Adhesive 242 to each of the four screws (3).
2 Install nose piece (1) into gear box (2) in
☞
2
1
direction of arrow.
Latch bar (4) (lever side) to face right
side of gear box (as viewed from the
front of the machine).
3 Install four screws (3). (torque = 18 Nm. /
159 in. lbs.).
3
4
Installing the
Spring Ring
1 Install spring ring (2) over the gear box (3)
from the front and install both retainers (1).
1
3
2
1
22
PAGE
REPAIR
INSTRUCTIONS
Installing
the handle
58-92-5300 d3
1 Press retainers (2) together on both sides
and install the handle (4).
1
2 Insert screw (1) in direction of arrow and
screw down knob (3).
2
3 4
Installing the
auxiliary handle
1 Install the auxiliary handle (1).
1
TEST RUN Run tool for a 5 minute run-in period.
ELECTRICAL TEST
– Perform electrical test on tool per Electrical and Mechanical Test Instructions, 58-92-0001.
23