DeWalt D25900K Service Manual Download

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Fault finding.

Unit Lacks Power.

Worn O-Rings on the Piston and Cylinder
Low Motor Speed, check No Load Amps
Worn Piston or Cylinder.
Faulty Electronics.

Motor Speed incorrect

Armature / Field faulty. Check No Load Amps
Faulty electronics
Fan Loose on Armature Shaft ( motor running to fast) .
Magnetic ring missing from fan (motor running to fast).

Unit will not run.

Brushes worn.
Electronics faulty.
Switch actuator rod not connected.
Switch actuator broken.

RUN TEST DATA.

No Load amps.

At Max Speed .

Min Max

Volts.

3.2

5.2

230/240

7.0

8.5

115/120

Flash Test with switch on.

4000v for 230/240v Double insulated units.
1500v for 120v unit with Earth.

Summary of Contents for D25900K

Page 1: ...r the 10KG Demolition Hammer D25900K This procedure is in Four main sections 1 General Information Tooling 2 Total Strip Down 3 Re assembly 4 Routine Servicing Tool Holder Anti Vibration Unit Gearbox Motor Unit Crankcase Piston Cylinder Beat Piece Ram Switch ...

Page 2: ... Re assembly Page 26 29 Gearbox and Crankshaft Page 30 33 Motor unit Page 34 36 Crankcase Piston and Gear Case Page 36 39 Switch Handle Page 40 41 Cylinder and Ram Page 42 44 Anti Vibration unit Page 45 SDS Spindle Page 46 47 Spindle Flange Page 48 50 Turning Sleeve Page 51 52 Tool Bit Locking assembly Page 53 57 Sliding Sleeve Snap Ring Page 58 59 Beat Piece Page 60 61 Tool Holder SA to Product R...

Page 3: ...n Tool Holder units although it can make the operation difficult if left attached because of the size and weight of the product If they are removed then the following should be noted q Only undo the 4 Screws 65 from the Anti Vibration Unit and remove the complete front assembly including the Tool Holder Unit from the Motor Housing q The Piston Crank Case Cylinder Anti Vibration Unit will be expose...

Page 4: ... 1 89 487241 00 1 104 323711 40 1 104 323711 40 1 108 487243 00 1 108 487243 00 1 109 487299 00 1 109 487299 00 1 800 578970 02 1 800 578970 02 1 Major Service Kit 115 Volt Major Service Kit 230 Volt Item No Part number Qty Item No Part Number Qty 8 487340 01 2 8 487340 01 2 32 487224 00 1 32 487224 00 1 36 487209 00 1 36 487209 00 1 49 487213 00 1 49 487213 00 1 52 323711 42 1 52 323711 42 1 58 3...

Page 5: ...ools required Soft faced mallet T Handled Torx Screw Drivers TX10 TX15 TX20 Long Nose pliers Torque wrench in Drive Torque Screwdriver Allen Keys Size various Circlip Pliers Internal External Press Vice Two legged puller ...

Page 6: ...d to fit Double Gear 42 in conjunction with a Press Will remove and replace the crank gear 43 in conjunction with a Torque Wrench Used to fit Armature Seal 36 Bearing 35 in conjunction with Service Tool 559621 99 559618 99 Motor assembly Tool Used to fit Motor Pot 2 Armature 1 ...

Page 7: ...Page 7 of 63 559621 99 Armature Seal Bearing assembly Tool Used to fit Seal 36 Bearing 35 559620 99 Spindle Seal Tool Holder assembly Tool Used to fit Seal 108 Spring Guide 98 ...

Page 8: ...Page 8 of 63 559619 99 Snap Ring assembly Tool Used to remove and fit Snap Ring 88 ...

Page 9: ... Tool Holder Assembly 111 a flat bladed screwdriver may be required to Gently lever the housing away from the Anti vibration unit q Beware that the internal components will fall out from the Tool Holder q Remove item 72 from inside the Housing q Remove the O Ring q Remove items 67 68 69 70 From inside the Tool Holder Unit ...

Page 10: ...Page 10 of 63 q Remove Beat Piece Bearing item 110 from Spindle 107 this may be tight q Remove O Ring 109 q Pull off Rubber Seal item 87 From end of Tool Holder Unit ...

Page 11: ...from Service Jig into the Tool Holder spindle be careful not to damage the Seal q Make sure that the insert stays in position otherwise the Seal inside the Spindle could be damaged then lower the Tool Holder onto the Jig q Place the Three legged part of the service tool over the threaded rod so that the legs rest on the edge of the Black Sliding Sleeve 91 ...

Page 12: ...ip pliers and a small flat bladed screwdriver prise the Snap Ring from the groove then maneuver it past the large groove to clear the Spindle q Remove the nut and the Three Legged part from the Jig q Remove the Snap Ring Do Not re use q Lift off the Sliding Sleeve Assembly q Remove the Washer 89 Do Not re use Remove Rubber Ring 90 and Locking Ring 92 ...

Page 13: ...epress Bush 96 and remove Locking Piece 92 x 2 Bush 96 and spring 97 q Remove the Tool Holder Assembly from the Service Jig Make sure the insert remains in place until the Tool Holder Unit is clear of the Threaded Spindle of the service Jig q Remove Jig Insert from The Tool Holder ...

Page 14: ...ft off housing complete with the Turning sleeve Assembly from Spindle 107 Remove Spring Guide item 98 from Turning Sleeve Assembly q Lever out Spring 99 BEWARE the Spring will be under tension q Remove SA Sleeve item 100 ...

Page 15: ... Pull off Turning sleeve item 101 from Housing q Remove O Ring 104 q Remove O Ring 74 If Spindle is to be re used then remove the following q O Ring 74 q Seal 108 This completes the strip down of the Tool Holder Unit ...

Page 16: ...to the Motor Housing q Use a broad flat bladed screwdriver to carefully lever the Anti Vibration unit from the Motor Housing q Beware there will be pressure from springs inside the Anti vibration unit This could cause the housing to be forced from the Motor Housing and some of the components to fall out q Beware also that the Piston will now be exposed when the unit is removed from Motor Housing q...

Page 17: ...d part at the wide end of Housing by the 4 boltholes q Remove Ram 76 Push through from the wider end of Cylinder using a non metallic object to avoid any damage to the Cylinder or Ram q Remove O Ring 77 from Ram q Remove outer O Ring 74 and inner 73 from the Cylinder This completes the strip down of the Anti Vibration unit ...

Page 18: ...q Remove Adapter 15 from Switch and remove Actuator Rod 14 from Trigger 12 q Remove cord clamp 25 2 Screws q Remove Switch Clamp 24 1 Screw q Cut and Remove the Cable Tie 23 from switch lead q Remove Switch 22 disconnect the Motor Lead 18 and Power cord 29 q Pull out Pin 12 Remove Trigger 13 Beware the two locating pins 17 will spring out when the Trigger is removed ...

Page 19: ...ic 54 2 Screws from inside Cover q Undo fan Screw 11 Grip outside edge of Fan Use protective gloves the edge of the Fan is very sharp Lift off fan 10 q Remove both the Terminals from the Brush Assembly Use long nose pliers to release the retaining clips q Remove the Switch lead SA 18 ...

Page 20: ... on the side ready to reassemble q Keeping the spring in this position will allow new brushes to be fitted waiting for re assembly q Disconnect the two short black leads from the Brush Assembly q Remove the 4 Screws 58 q Holding the Brush Assembly 3 lift clear of Armature shaft The Brush Holders are not available as separate parts q Push out Bearing 5 and insulator 4 from Brush assembly ...

Page 21: ... O ring 52 This must be replaced q Remove Piston SA 51 This is only possible if the Anti vibration unit has been removed Position the CrankShaft Pin so the Con Rod can be lifted off and removed through the front of Main Housing q To dismantle Piston push Pin 47 through from either side and lift Piston off Con Rod 38 Lever out Knob 48 x 2 Remove O Ring 49 ...

Page 22: ... cover 21 q Remove Snap Ring 16 from Armature shaft groove this must be spread wide enough to clear the splines on the Armature shaft q The Snap Ring must not be reused If replacing the Armature a new Snap ring will be supplied and fitted q Push Armature though bearing using a Press and tube ...

Page 23: ...Position the Main casting on to the Jig 559617 99 q Make sure the pin on the CrankShaft 45 locates into the recess on the Jig q Then locate the socket part of the Jig into the large Gear 43 q Remove Gear Anti clockwise q Remove Double Gear 42 using a Puller ...

Page 24: ...ng a press and a suitable size drift q Remove the Main casting from the service jig q Remove the CrankShaft assembly using a press q Push through from the outside The CrankShaft bearings can not be replaced due to misalignment problems when refitting If required the complete housing will have to be replaced ...

Page 25: ...Page 25 of 63 q Remove the Circlip 34 from the Armature Bearing q Press out the Armature Bearing 35 q Remove the seal 36 This must be replaced This completes the Full Strip Down of the product ...

Page 26: ... 559621 99 q Make sure the Ring Seal 46 is fitted to Crank Shaft SA 45 Place Main Housing on Press base so the threaded part of the Crank Shaft can be pushed through q Press Crankshaft into Main Housing to its limit Check the shaft rotates freely in the bearings q Fit New O Ring 79 to front of Main Housing ...

Page 27: ...re the pin on the CrankShaft 45 locates into the recess on the Jig q Fit new Armature Seal to Main Housing Use Service Tool and press 559621 99 Make sure the metal insert is facing up q Wipe Grease 800 into the Metal insert before fitting Bearing q Fit Armature Bearing 35 again using Service tool 559621 99 q Fit CirClip 34 ...

Page 28: ...324821 03 q Press one Bearing 41 into Double Gear to its limit q Fit both Spacers into the Gear Assembly one resting on the inner and the other on the outer race of the Bearing one inside the other q Fit the second Bearing make sure to clear the groove for the Circlip q Fit Cirlip The Main housing should still be on the Service Jig 559617 99 ...

Page 29: ...vice before tightening the Large Gear To do this Replace the bar on the underside Crank Gear 43 579783 00 q Fit the Large Gear onto the threaded part of the CrankShaft making sure the teeth mesh correctly with the Double gear q Fit Socket part of Service Jig to the Gear and tighten clockwise to a torque of 14 Nm Remove Housing from Service Jig This completes the Re assembly of the Gearbox Re assem...

Page 30: ...eplaced it will be supplied with the Ring fitted q Place main Housing onto Service Jig 55918 99 q Place Armature into Main Housing through the Bearing making sure the splines mesh with the Double Gear q Press Armature into Bearing until the Snap Ring has passed through the Bearing and located correctly into the groove ...

Page 31: ...the Main Housing making sure the Seal 33 remains in place q Push down until seated correctly q Fit the Bearing 5 into the Insulator 4 q Then Fit to the Brush Assembly q If not already done fit new Brushes to the Brush Assembly and leave in this position q Connect the Lead to the tag on the Brush Holder ...

Page 32: ...Ensure the two short black wires are positioned one either side of the Brush Assembly through the recess as shown q Then connect to the terminal on the Brush holder q The remaining two long wires with the black terminal attached pass through the recess and under the wire trap as shown q Release the brushes onto the Armature make sure the Spring is behind the Brush ...

Page 33: ... pass the wire under the wire trap q Fit four new Screws 58 and tighten to 3 Nm q Fit the fan 10 to the Armature shaft and tighten the Screw to 5 Nm Grip outside edge of Fan Use protective gloves the edge of the Fan is very sharp IMPORTANT NOTE MAKE SURE THE FAN IS TIGHT ON THE ARMATURE SHAFT This compleates the Motor unit assembly ...

Page 34: ... SA 579779 00 Piston 50 579774 00 Con Rod 38 487234 00 O Ring 49 487213 00 Pin 47 487208 00 Knob 48 x 2 487228 00 q Fit the two white knobs 48 into the ends of the pin 47 q Grease all around the piston inside and out with 5 Grams of item 800 Place the smaller diameter of the Con Rod into the piston and push the Pin through until it is centered q Grease the larger diameter hole in the Con Rod q Fit...

Page 35: ...in this position ready to fit the Anti Vibration unit q Distribute 39 Grams of Item 800 Grease into CrankCase q Make sure a new O Ring 52 is fitted then Refit the Cover 53 Tighten Screws to 3 Nm q Fit Electronics into the motor cover line up the D in the Module spindle with the D in the Cover q Fit the cover to the Main Housing q Tighten the Screws to 3 Nm ...

Page 36: ...new Seal 32 to the Main Housing make sure the seal fits into the groove in the housing q Fit cover 21 q Distribute 39 Grams of item 800 Grease over the Gears q Fit Gear Case Cover 30 Tighten screws to 3 Nm This completes the reassemble of the CrankCase Piston and Gearcase ...

Page 37: ...tor Leads to the switch q Fit the Power Cord leads to the Switch q Position suppressor as shown q Locate Switch into position q Fit Switch Clamp q Fit Power Cord and cord Clamp Tighten the screws to 1 8 Nm q Locate the Motor Cable and Cable Tie as shown ...

Page 38: ...r into the housing in the Brush Assembly q Line up the holes and push the pin 12 through the Housing and into the Trigger and centralize q Push the two springs in and press the trigger into the housing until it clicks twice q Locate the actuator rod 14 into the trigger q Position the Adapter 15 over the button on the Switch and slide over until it clicks ...

Page 39: ...Page 39 of 63 q Fit Switch Handle Cover 19 q Tighten the 6 Screws 58 to 3Nm q Tighten the 2 Screws 26 to 1 8 Nm This completes the reassemble of the Switch Handle Assembly ...

Page 40: ... Housing 78 579769 00 Cylinder 75 579770 00 O Ring 74 323711 41 Ram 76 579780 00 O Ring 73 487279 00 O Ring 77 487296 00 q Fit newO Ring 74 over wide end of Cylinder q Fit new O Ring 73 to groove on inside of Cylinder q Grease the inside of the Cylinder with item 800 q Grease the Ram 76 and fit a new O Ring 77 ...

Page 41: ...o push the Ram down until it reaches the bottom Beware grease will come out of the holes in the Cylinder q Make sure the inside of the Cylinder is still coated with Grease q Grease the inside of the Housing around the teeth q Fit the Cylinder into the Housing 78 with the thinner diameter first Push down until the larger diameter sits in the teeth This completes the reassemble of the Cylinder and R...

Page 42: ...uide grooved 86 576488 00 Spring Guide smooth 80 487293 00 q Fit the 2 Guides 82 to the Counterweight 83 with the tapered diameter into the internal bore of the Counterweight q Fit the smooth Spring Guide into the housing over the Cylinder with the recess facing up q Lightly grease both ends of one Spring 81 place the spring over the Cylinder and into the Housing ...

Page 43: ...ounterweight SA place over the cylinder and onto the Spring q Lightly grease both ends of the remaining Spring 81 place over Cylinder onto the Counterweight q Place the Grooved Spring Guide 86 onto the Spring with the recess facing down ...

Page 44: ...the internal parts in position Maneuver the Piston into the Cylinder and lower onto the Main Housing q Make sure O Ring is in place q Fit the 4 Screws 65 and tighten to 17 Nm q The correct sequence is to tighten the screws in opposite corners in turn q Pick up the black plastic Housing 66 Pull the split apart and line it up with the narrow groove facing the Gearbox slide over the housing until it ...

Page 45: ...tted Spindle 579773 00 Beat piece seal 487243 00 q Fit new seal 108 into Spindle 107 using the Service Tool 559620 99 q Make sure the Seal is fitted to the Service Tool in the correct position with the spring against the shoulder see photo q Lightly Grease the outside of the seal q Push Seal into spindle until seated correctly ...

Page 46: ...ing 74 small 38 x 2 5 323711 41 O Ring 71 large 43 x 5 5 487298 00 O Ring 104 323711 40 58 x 2 0 q Fit a new small O Ring 74 into the groove under the Hexagon on the outside of the Spindle q Smear a small quantity of grease item 800 around the wide end of the spindle and on the inside ...

Page 47: ...ing 74 into recess q Fit new O Ring 104 to the groove in the flange q Place the Flange 103 over the thin end of the spindle 107 and push down fully q Hold Flange still and turn Spindle until corner of hexagon sits in line with a hole in the flange base This completes the Spindle and Flange Re assembly ...

Page 48: ...ring 99 487289 00 Turning Sleeve 101 487237 00 Spring Guide 98 487268 00 q Place the Locking Sleeve 100 on the bench with the teeth down seat the hexagon coil of the spring on the hexagon of the sleeve q The angled end the spring must be facing down and lying next to the lip ...

Page 49: ...e hole q Using the Service Tool place the hexagon end into the hexagon of the locking sleeve Twist the Service Tool to the right keeping slight downward pressure on until you feel the locking sleeve move down into the turning sleeve q Remove the Service tool very carefully and hold the spring in place otherwise it can jump out of its location q Make sure the angled end of the spring is pushed down...

Page 50: ...e plastic guide in place to prevent the spring becoming dislodged then place the Turning Sleeve SA over the Spindle with the ridged diameter facing down q Make sure the hexagon of the Spindle lines up with the hexagon in the Sleeve SA q Press the Turning sleeve SA down until it clicks into place q Check that the Turning Sleeve twists to the right and the spring returns This completes the Turning S...

Page 51: ... with the tapered end up q Fit the washer 96 over the spindle so it lies on the spring with the recess up q Push down the washer 96 until it is clear of the two slots in the spindle q Lightly grease the two slots before fitting the Locking Pieces q Place the rounded straight edge of one Locking Piece 95 into each slot in the spindle q Release the pressure on the washer and let it rest on the locki...

Page 52: ...h Damper 94 over the spindle so it rests on the locking pieces with the taper facing down q Place the Spring 93 over the spindle and let it rest on the locking sleeve This completes the Re assembly of the Tool Bit Locking assembly ...

Page 53: ... 00 Damper 90 486244 00 Washer 89 487241 00 Seal 87 487238 00 Snap Ring 88 487205 00 q Place the Locking Bush 92 into the wide end of the Sliding Sleeve 91 and make sure that it is seated correctly q Turn the Sliding Sleeve over q Fit the Chisel Damper 90 q Place a new Washer 89 on top of the Damper with the recess facing out ...

Page 54: ...t from Service Jig into the spindle be careful not to damage the Seal q Place Flange and Spindle SA on Service Jig q MAKE SURE THE PROTECTIVE INSERT STAYS INSIDE THE SPINDLE WHILE THE FLANGE IS LOWERED ONTO THE SERVICE TOOL OTHERWISE THE SEAL WILL BE DAMAGED BY THE THREAD ON THE STUD ...

Page 55: ...the center of the Washer Make sure the Washer has the recess facing up HOLD IN THIS POSITION THROUGHOUT THE FOLLOWING OPERATION q Screw the Cone Shaped part of the Service jig down until it comes in contact with the Spindle and lock with a spanner DO NOT OVER TIGHTEN q Fit New Snap Ring 88 over Cone of the Service Jig ...

Page 56: ...is in the Groove in the Spindle Four clicks should be heard q The Top of the threaded bar and the top of the Nut should be flush when the Snap Ring is in the correct position q Remove the nut and spacer washer from Jig q Undo the cone and remove from Jig q Making sure the Insert stays inside the housing Lift off the complete Assembly with the collet still attached to the Spindle Now pull off colle...

Page 57: ... Ring is correctly seated q Fit the Seal 87 q Check that the Sliding Sleeve 91 can be pulled down and returns to its start position q Check the Turning Sleeve rotates anti clockwise This completes the Sliding Sleeve Snap Ring Re assembly ...

Page 58: ...832 00 Bush Damper 70 579786 00 Damper 69 487288 00 O Ring 109 487299 00 35 x 5 Washer 68 487270 00 Bearing 110 579785 00 q Grease all round the inner bore of the Spindle with item 800 q Fit new O Ring 109 push down until it lies in the recess then re grease the inner bore of the Spindle ...

Page 59: ...Push the smallest diameter into the bore of the tool holder until it reaches its limit q Coat the Beatpiece with grease 800 up to the smallest ridge q Then place the greased end of the Beatpiece into the Tool Holder Then lightly grease the top end of the Beatpiece and inner boar of the Spindle ...

Page 60: ...eaches its limit q Place the Washer 68 into the Bush 70 with the internal taper facing up q Coat the outside diameter of the Bush Damper Assembly q with the small diameter facing up place over the Beatpiece and into the tool holder Assembly The Tool Holder Assembly is now ready to fit onto the Anti Vibration Unit ...

Page 61: ...with the O Ring facing up Make sure the internal components of the Tool Holder do not fall out when fitting to the Front Housing q Fit the Tool Holder Unit to the Front Housing lining up the six screw holes q Tighten the 6 Screws in this Sequence to 10 Nm This competes the Re assembly of the D25900Hammer 1 2 3 5 4 6 ...

Page 62: ...Ring 323711 44 79 on Main Housing Replace O Ring 487296 00 77 on Ram Replace O Ring 487297 00 73 inside Cylinder Replace O Ring 487299 00 109 inside Spindle Replace Seal 487243 00 108 inside Spindle Lubricate all the above and replace the Grease 578970 02 140g 800 in the Gearbox and Crankcase Replace Washer 487241 00 89 Snap Ring 487205 00 88 Replace rubber nose 487238 00 87 Replace Brushes 487340...

Page 63: ...d Amps Faulty electronics Fan Loose on Armature Shaft motor running to fast Magnetic ring missing from fan motor running to fast Unit will not run Brushes worn Electronics faulty Switch actuator rod not connected Switch actuator broken RUN TEST DATA No Load amps At Max Speed Min Max Volts 3 2 5 2 230 240 7 0 8 5 115 120 Flash Test with switch on 4000v for 230 240v Double insulated units 1500v for ...

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DeWalt D25900K, Service Manual

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