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Fein BOS 16, Repair Instructions, Page: 24 / 55

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Fein BOS 16 Repair Instructions Download Page 24

BOS 16; BOS 16-2 

 

6.  Disassembly 

 

C-SC_CSSM 

Version 1.0 

13.11.2013 

All rights reserved by FEIN, especially in case of industrial rights registration.  
FEIN retains all rights of disposal, such as copying and circulation

. 

Page 

24

 of 

55

 

 

Disassembling gearbox (only applies to BOS 16-2) 

 

 

 

 

1.  Slide locking plate (1) up and out. 

2.  Pull out switch pushbutton (2). 

3.  Remove pin (3). 

4.  Take out switch module (4). 

5.  Take round seal ring (5) off switch pushbutton. 

Tools: 

-  Slotted screwdriver 

 

 

1

 

5

 

2

 

4

 

3

 

Summary of Contents for BOS 16

Page 1: ...2 Repair instructions C SC_CSSM Version 1 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 1 of 55 ...

Page 2: ...e of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 2 of 55 1 Models described 2 Technical data 3 Notes and requirements 4 Tools required 5 Lubricants and auxiliary substances required 6 Disassembly 7 Assembly 8 Troubleshooting 9 Connection diagram ...

Page 3: ...eserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 3 of 55 These instructions describe how to repair the following models Model Order number BOS 16 7 205 47 00 23 0 BOS 16 2 7 205 49 00 23 0 ...

Page 4: ...ical data The complete technical data can be found in the operating instructions for the model Test data Up to date test data for all models can be found on the FEIN Extranet Customer Service Repair Guides Lubricants The lubricants and container sizes available from FEIN can be found on the FEIN Extranet Customer Service Repair Guides Lists of spare parts Lists of spare parts and exploded views ar...

Page 5: ...rical training Only use original FEIN spare parts Provisions Please note that power tools may only be repaired maintained and checked by a trained electrician as improper repair can result in serious risks to the user The provisions set out in DIN VDE 0701 0702 should be observed after repairs The relevant accident prevention regulations of the employers liability insurance associations are to be ...

Page 6: ...et cap 6 41 04 150 00 8 Open ended spanner size 17 sanded 6 29 03 002 00 9 Assembly aid 6 41 22 121 01 0 Socket wrench 10 mm Chuck cone 19 mm 6 41 07 019 00 7 Plastic hammer 26 mm chuck cone 6 41 07 026 00 0 Arbor press Long nosed pliers 2x slotted screwdriver Inner puller 10 mm Slide hammer Circlip pliers Sleeve 7 mm inner diameter Sleeve 17 mm inner diameter Sleeve 20 mm inner diameter 24 mm out...

Page 7: ...e of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 7 of 55 Standard tools Sleeve 25 mm inner diameter 35 mm outer diameter Sleeve 38 mm inner diameter 43 mm outer diameter Ball bearing support 8 mm inner diameter Ball bearing support 11 mm inner diameter ...

Page 8: ...s required C SC_CSSM Version 1 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 8 of 55 Lubricants Grease 0 40 11 301 00 5 30 g Gearbox ...

Page 9: ...rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 9 of 55 Disassembling handle 1 Unscrew handle 1 2 Pull off sleeve 2 3 Remove screw 3 4 Pull off locking ring 4 1 2 3 4 ...

Page 10: ...by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 10 of 55 Disassembling quick clamping drill chuck 1 Unscrew quick clamping drill chuck 1 Tools Socket wrench 10 mm Open ended spanner size 17 sanded 1 ...

Page 11: ... especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 11 of 55 Disassembling carbon brushes 1 Unscrew screw 1 and remove cover 2 2 Lift spring 3 to one side 3 Pull out carbon brush 4 Tools Torx T15 Assembly aid 1 4 3 2 ...

Page 12: ... especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 12 of 55 Disassembling carbon brushes 1 Pull out cable 1 of electronics 2 Pull out plug contact 2 of carbon brush and remove carbon brush Tools Long nosed pliers 1 2 ...

Page 13: ...rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 13 of 55 Disassembling gearbox housing 1 Loosen four screws 1 2 Pull off complete gearbox housing 2 Tools Torx T20 1 2 ...

Page 14: ...case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 14 of 55 Disassembling handle 3 Unscrew the five screws 1 4 Remove handle half shell 2 5 Loosen screw 3 and remove cable clamping piece 4 6 Remove handle half shell 5 Tools Torx T20 T15 1 2 3 4 5 ...

Page 15: ...specially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 15 of 55 Disassembling the electronics 1 Prise out electronics 1 2 Pull blue cable 2 out of switch 3 Pull black cable 3 out of switch Tools 2x slotted screwdriver 1 2 3 ...

Page 16: ...gistration FEIN retains all rights of disposal such as copying and circulation Page 16 of 55 Disassembling motor housing 1 Remove the two screws 1 and take off carbon brush holder 2 Take out blue cable 2 3 Unscrew the two screws 3 and remove air guide ring 4 4 Remove stator from motor housing Tools Torx T15 T20 Plastic hammer 1 2 3 4 ...

Page 17: ...retains all rights of disposal such as copying and circulation Page 17 of 55 Disassembling gearbox housing 1 Remove armature 1 from gearbox housing 2 2 Disconnect gearbox housing from intermediate bearing 3 Remove seal 3 4 Pull out the two dowels 4 5 Remove the three grooved ball bearings 5 Tools Plastic hammer Inner puller Slide hammer 4 4 3 1 2 5 ...

Page 18: ...l such as copying and circulation Page 18 of 55 Disassembling armature 1 Pull off grooved ball bearing 2 together with sealing ring 1 from armature 2 Remove plate 3 3 Pull off ring magnet 6 by hand 4 Prise off sleeve 5 with two slotted screwdrivers 5 Pull off grooved ball bearing 4 Tools Drawing off socket cap Chuck cone 19 mm Chuck cone 26 mm 2x slotted screwdriver 2 1 3 4 5 6 ...

Page 19: ...irculation Page 19 of 55 Disassembling gearbox housing only applies to BOS 16 1 Remove circlip 1 2 Remove clutch 2 3 Take all gear wheels out of gearbox housing 4 Remove the two grooved ball bearings 3 5 Remove circlip 4 6 Press shaft 5 with grooved ball bearing out of gearbox housing Tools Circlip pliers Inner puller Slide hammer Arbor press Sleeve 38 mm inner diameter 43 mm outer diameter 1 4 5 ...

Page 20: ...lly in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 20 of 55 Disassembling shaft only applies to BOS 16 1 Remove circlip 1 2 Press grooved ball bearing 2 off shaft 3 Tools Circlip pliers Arbor press Sleeve 24 mm inner diameter 1 3 2 ...

Page 21: ... rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 21 of 55 Disassembling gearbox only applies to BOS 16 2 1 Remove clutch 1 2 Remove circlip 2 Tools Circlip pliers 1 2 ...

Page 22: ...FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 22 of 55 Disassembling gearbox only applies to BOS 16 2 1 Remove disc 1 2 Remove gear wheel 2 3 Remove the three balls 3 between shaft and gear wheel 1 3 2 3 ...

Page 23: ...specially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 23 of 55 Disassembling gearbox only applies to BOS 16 2 1 Remove disc 1 2 Remove gear wheel with shaft 2 3 Remove the three balls 3 between shaft and gear wheel 1 2 3 3 ...

Page 24: ...registration FEIN retains all rights of disposal such as copying and circulation Page 24 of 55 Disassembling gearbox only applies to BOS 16 2 1 Slide locking plate 1 up and out 2 Pull out switch pushbutton 2 3 Remove pin 3 4 Take out switch module 4 5 Take round seal ring 5 off switch pushbutton Tools Slotted screwdriver 1 5 2 4 3 ...

Page 25: ...ation FEIN retains all rights of disposal such as copying and circulation Page 25 of 55 Disassembling gearbox only applies to BOS 16 2 1 Remove circlip 1 2 Press shaft 2 out of gearbox housing 3 Remove the two ball bearings 3 Tools Circlip pliers Arbor press Sleeve 38 mm inner diameter 43 mm outer diameter Inner puller Slide hammer 1 3 2 ...

Page 26: ...ights registration FEIN retains all rights of disposal such as copying and circulation Page 26 of 55 Disassembling shaft only applies to BOS 16 2 1 Remove disc 1 2 Remove circlip 2 3 Slide sleeve 3 down and remove it with the draw keys 4 Tools Circlip pliers Arbor press Sleeve 38 mm inner diameter 43 mm outer diameter 1 2 3 4 ...

Page 27: ...ly in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 27 of 55 Disassembling shaft only applies to BOS 16 2 1 Remove circlip 1 2 Press grooved ball bearing 2 off shaft 3 Tools Circlip pliers Arbor press Sleeve 24 mm inner diameter 1 2 3 ...

Page 28: ...ghts reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 28 of 55 Disassembling gear wheel 1 Press gear wheel 1 off spur gear shaft Tools Arbor press Sleeve 22 mm inner diameter 1 ...

Page 29: ...ghts reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 29 of 55 Assembling gear wheel 1 Press spur gear shaft 1 into gear wheel Tools Arbor press Sleeve 17 mm inner diameter 1 ...

Page 30: ...l rights registration FEIN retains all rights of disposal such as copying and circulation Page 30 of 55 Assembling shaft only applies to BOS 16 1 Press grooved ball bearing 1 on to shaft 2 2 Secure grooved ball bearing with circlip 3 Tools Circlip pliers Arbor press Sleeve 21 mm inner diameter 37 mm outer diameter 3 2 1 ...

Page 31: ...lation Page 31 of 55 Assembling gearbox only applies to BOS 16 1 Press grooved ball bearing 1 with shaft into gearbox housing 2 Insert circlip 2 3 Press in the two grooved ball bearings 3 4 Insert all gear wheels and clutch in gearbox housing Check clutch before inserting see test instructions 5 Insert circlip 4 Tools Circlip pliers Arbor press Sleeve 25 mm inner diameter 35 mm outer diameter 4 1 ...

Page 32: ...industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 32 of 55 Assembling shaft only applies to BOS 16 2 1 Press the grooved ball bearing 1 onto the shaft 2 Assemble circlip 2 Tools Circlip pliers Arbor press Sleeve 21 mm inner diameter 37 mm outer diameter 1 2 ...

Page 33: ... of disposal such as copying and circulation Page 33 of 55 Assembling shaft only applies to BOS 16 2 1 Slide sleeve 1 on to shaft 2 Rotate sleeve such that the three dowels 2 lie inside the recesses 3 3 Insert the three draw keys 4 such that the two grooves 5 under the sleeve are adjacent Fix draw keys with a drop of grease Insert draw keys one at a time 2 1 3 4 5 ...

Page 34: ...rial rights registration FEIN retains all rights of disposal such as copying and circulation Page 34 of 55 Assembling shaft only applies to BOS 16 2 1 Rotate sleeve 1 on to draw keys 2 2 Slide sleeve 1 with draw keys in direction of arrow 3 Assemble circlip 3 4 Slide disc 4 on to shaft Tools Circlip pliers 2 1 1 4 3 ...

Page 35: ...embling gearbox only applies to BOS 16 2 1 Press grooved ball bearing 1 with shaft into housing 2 Assemble circlip 2 3 Assemble disc 3 4 Press in the two grooved ball bearings 4 5 Pull out sleeve 5 6 Insert switch module 6 in groove of sleeve 7 Insert guide pin 7 8 Slide round seal ring 8 into groove of switch pushbutton 9 Tools Circlip pliers Arbor press Sleeve 25 mm inner diameter 35 mm outer di...

Page 36: ...hts registration FEIN retains all rights of disposal such as copying and circulation Page 36 of 55 Assembling switch pushbutton only applies to BOS 16 2 1 Insert switch pushbutton Ball 1 of switch pushbutton must run inside guide 2 of housing Projection 3 of switch pushbutton must lie inside recess 4 of switch module 1 2 3 4 ...

Page 37: ...d circulation Page 37 of 55 Assembling shaft only applies to BOS 16 2 1 Slide locking plate 1 into groove on switch pushbutton Insert locking plate such that curvature faces inside of tool 2 Turn switch pushbutton to position 1 3 Insert the three balls 2 in recesses 3 of shaft Fix balls with a drop of grease 4 Slide gear wheel 4 on to shaft 5 Insert disc 5 Tools Slotted screwdriver 1 2 3 4 5 1 ...

Page 38: ...EIN retains all rights of disposal such as copying and circulation Page 38 of 55 Assembling gearbox only applies to BOS 16 2 1 Insert shaft 1 and gear wheel 2 With switch pushbutton switch to second gear 3 Insert the three balls 2 in recesses 3 of shaft Fix balls with a drop of grease 4 Slide gear wheel 4 on to shaft 5 Insert disc 5 2 3 4 1 5 ...

Page 39: ...ghts reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 39 of 55 Assembling gearbox only applies to BOS 16 2 1 Assemble circlip 1 2 Insert the clutch 2 Tools Circlip pliers 2 1 ...

Page 40: ...rights of disposal such as copying and circulation Page 40 of 55 Assembling gearbox housing 1 Press in the three grooved ball bearings 1 2 Insert the two dowels 2 3 Fit seal 3 in the correct position 4 Fill gearbox housing 4 with 30 g of grease 5 Join gearbox housing and intermediate bearing Tools Arbor press Plastic hammer Grease 0 40 11 301 00 5 2 2 3 1 4 ...

Page 41: ...osal such as copying and circulation Page 41 of 55 Assembling the armature 1 Fit plate 1 2 Press on grooved ball bearing 2 3 Press on sealing ring 3 4 Press on grooved ball bearing 4 5 Press on sleeve 5 6 Press magnet 6 on to sleeve by hand Tools Ball bearing support 8 mm inner diameter Ball bearing support 11 mm inner diameter Sleeve 7 mm inner diameter 2 3 1 4 5 6 2 4 3 ...

Page 42: ... 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 42 of 55 Assembling the armature 1 Insert armature 1 into gearbox housing 2 1 2 ...

Page 43: ...sembling stator 1 Route black cable 1 behind blue cable to fix black cable in place 2 Press stator 2 into motor housing and at the same time pull out both cables Cables 4 of stators must be to the right of type plate 3 Press blue cable into appropriate recess 5 4 Insert air guide ring 6 and secure with the two screws 7 1 8 0 25 Nm Tightening the screws 7 presses the stator fully into the housing T...

Page 44: ... FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 44 of 55 Assembling carbon brush holders 1 Insert the two carbon brush holders 1 and secure each with the appropriate screw 1 2 0 15 Nm Tools Torx T15 1 ...

Page 45: ...stration FEIN retains all rights of disposal such as copying and circulation Page 45 of 55 Assembling the electronics 1 Press electronics 1 on to motor housing in correct position The hooks must audibly click into place 2 Connect blue cable 2 as shown in connection diagram 3 Connect black cable 3 as shown in connection diagram 2 3 1 ...

Page 46: ... circulation Page 46 of 55 Assembling handle 1 Slide on lower part of handle 1 2 Connect supply cable to switch as shown in connection diagram 3 Press cables into appropriate holders see page 47 4 Insert cable kink guard 2 in appropriate recess 5 Insert switch 3 and position cables in guides see page 47 6 Insert cable clamping piece 4 and secure with screw 5 1 8 0 25 Nm Tools Torx T15 5 4 3 2 1 ...

Page 47: ... Assembly C SC_CSSM Version 1 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 47 of 55 Cable routing ...

Page 48: ...specially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 48 of 55 Assembling handle 1 Fit upper part of handle 6 2 Screw in the two screws 4x48 7 2 5 0 3 Nm 3 Screw in the three screws 4x18 8 2 5 0 3 Nm Tools Torx T20 7 6 8 ...

Page 49: ...trial rights registration FEIN retains all rights of disposal such as copying and circulation Page 49 of 55 Assembling gearbox housing 1 Insert gearbox housing with armature 1 Make sure the carbon brushes are not assembled before the armature is inserted 2 Secure with the four screws 2 2 0 0 25 Nm Tools Torx T20 2 1 ...

Page 50: ...ally in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 50 of 55 Assembling carbon brushes 1 Connect cable of carbon brushes 1 on both sides 2 Connect cable 2 of electronics as shown in connection diagram Tools Long nosed pliers 2 1 ...

Page 51: ...trial rights registration FEIN retains all rights of disposal such as copying and circulation Page 51 of 55 Assembling carbon brushes 1 Insert carbon brushes 1 on both sides 2 Raise springs 2 to carbon brushes 3 Position covers 3 on both sides and secure with screws 4 1 2 0 15 Nm Tools Torx T15 Assembly aid 2 1 4 3 ...

Page 52: ...y in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 52 of 55 Assembling quick clamping drill chuck 1 Assemble quick clamping drill chuck 1 Tighten drill chuck to 50 Nm Tools Socket head screws 10 mm Open ended spanner size 17 sanded 1 ...

Page 53: ...ghts reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 53 of 55 Assembling handle 1 Slide on locking ring 1 2 Insert screw 2 3 Slide on sleeve 3 4 Screw down handle 4 1 2 3 4 ...

Page 54: ...2 8 Troubleshooting C SC_CSSM Version 1 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 54 of 55 ...

Page 55: ... 9 Connection diagram C SC_CSSM Version 1 0 13 11 2013 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation Page 55 of 55 ...

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