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FEIN

– REPAIR - TOOLS

All rights reserved by FEIN, especially in case of industrial rights registration.
Any power of disposition such as copying and right of transfer is situated with FEIN.

Sahre / MVK 05 / 2011

Insert coolant pump, hoses and distributor in foam cover
Connect earthing conductor contact to coolant pump
Insert motor cable through opening
Attach foam cover and metal cover and screw down

Warning - do not jam any cables when attaching the two covers !!!!!!!!!!!

5.5. Assembly - Electronics / Tank

Tool:
- Torx 20 screwdriver
- PH2 cross-tip screwdriver

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Summary of Contents for KBM80U

Page 1: ...R TOOLS All rights reserved by FEIN especially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 KBM 80 U KBM 80 Auto ...

Page 2: ...cal data 2 Maintenance 3 General checks 4 Disassembly 4 1 Disassembly Tank Electronics 4 2 Disassembly Feed unit 4 3 Disassembly Drill motor 4 4 Disassembly Gearbox 4 5 Disassembly Drill jig 5 Assembly 5 1 Assembly Drill jig 5 2 Assembly Drill motor 5 3 Assembly Gearbox 5 4 Assembly Feed unit 5 5 Assembly Electronics Tank 6 Tools You will find a drawing and list of spare parts online www fein de F...

Page 3: ...AIR TOOLS All rights reserved by FEIN especially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 1 Technical data ...

Page 4: ...PAIR TOOLS All rights reserved by FEIN especially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 2 Maintenance ...

Page 5: ...s Rated voltage 220 240 V Test voltage 10 230 V Idling current 10 3 40 4 00 A 3 7 A Idling speed first gear 5 162 198 rpm 180 rpm Main switch on Voltage on X5 10 90 110 VDC 100 VDC Release force of magnet 3 500 N Current consumption of magnetic foot Approx 0 15 A AC Main switch on motor on Voltage on X5 10 180 220 VDC 200 VDC Resistance of magnetic foot per coil 22 ohms Test voltage motor without ...

Page 6: ...ial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 Disassembly Before starting to repair or disassemble the tool you must remove the mains plug from the socket and remove the drill bit from the tool ...

Page 7: ...isposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics Lift coolant tank up with screwdriver and pull upwards by hand until tank is disengaged from lock at top end Yellow circle The tank can then be removed from the tool Tools slotted screw driver ...

Page 8: ...registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics Remove screws from cover of drill jig Pull out coolant hose Fold metal cover and foam cover forwards and down Tools torx screw driver TX 20 ...

Page 9: ...as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics Remove cable from terminal Pull out coolant hose Remove plug for coolant pump and speed cable from circuit board Disconnect earthing conductor from coolant pump Tools slotted screw driver small cross sloted screw driver PH 1 ...

Page 10: ...sposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics Remove electronics cover with coolant pump and hoses Loosen and remove screws for fall protection on dove tail guide Remove cover of drill jig and drill motor from drill jig Tools allen key 3 mm ...

Page 11: ...on such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics Disconnect mains cable Remove plug for magnetic field monitoring Remove plug from magnetic foot Remove gearbox motor plug KBM 80 auto only Remove circuit board s earth contact Tools slotted screw driver small ...

Page 12: ...wer of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 1 Disassembly Tank Electronics After all the connections from the circuit board to the switches and other components have been disconnected the circuit board can now be removed from the foam and the drill jig ...

Page 13: ...ng torque during assembly 1 Nm must be complied with otherwise the automatic feed will not work correctly Remove Loctite residue on threaded bar and nut and clean parts During assembly moisten threaded bar with Loctite 242 then tighten nut to 1 Nm Remove spider with feed motor Warning when removing the spider carefully slide the feed motor connection cable through the jig housing the plug is relat...

Page 14: ...trial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Remove screws from motor fastening Prise motor out of housing with screwdriver Tools allen key 3 mm slotted screw driver ...

Page 15: ...y power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Loosen set screw Remove worm with ball bearing and spacer from motor shaft Feed motor is only available as a spare part in complete form see photo on right Tools allen key 2 mm ...

Page 16: ...rial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Remove housing from bearing by gently striking with plastic hammer Remove circlip Tools plastic hammer outer circlip plier ...

Page 17: ...strial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Remove worm wheel from drive shaft Remove balls Remove circlip Prise ball bearing out of bearing seat with screwdriver ...

Page 18: ...IN especially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Remove set screw Remove spring and ball Tools allen key 4 mm ...

Page 19: ... rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 2 Disassembly Feed unit Unscrew handles Drive out dowel pins with punch Remove switch bar Remove control rod from drive shaft Tools steel hammer drive pin ...

Page 20: ...tration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 3 Disassembly Drill motor Remove 2 screws from cover cap Remove cover Loosen and remove screw for securing housing Remove safety shutdown mat Tools cross slotted screw driver PH 2 ...

Page 21: ...er of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 3 Disassembly Drill motor Lift up and turn console electronics Remove speed cable plug contact and motor electronics Slide up protective hose and remove lock Pull protective hose down and out and remove housing ...

Page 22: ... of transfer is situated with FEIN Sahre MVK 05 2011 4 3 Disassembly Drill motor Remove motor electronics from motor housing Remove both plug contacts from motor electronics Loosen screw on carbon holder cover and remove carbon holder cover Pull plug contact out of carbon brush and remove carbon brush Tools cross slotted screw driver PH 2 flat plier ...

Page 23: ...ration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 3 Disassembly Drill motor Loosen 4 screws on gearbox housing Remove gearbox housing careful it is bonded with Loctite 5188 surface seal Remove and replace grease Tools allen key 4mm ...

Page 24: ... copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 3 Disassembly Drill motor Loosen 4 screws on intermediate bearing Remove intermediate bearing with armature from motor housing Clamp armature in vice with aluminium jaws Disconnect intermediate bearing from armature by striking with hammer Tools plastic hammer ...

Page 25: ...or Remove spacer if necessary from ball bearing with circlip pliers Carefully press out magnet ring risk of breakage Remove bearing and replace if necessary Remove 2 screws from field coil Remove plug connection brown cable from carbon holder Remove contact plug white from holder and slowly pull out of motor housing with field coil to do this all cables must be routed between the ribs of the housi...

Page 26: ... situated with FEIN Sahre MVK 05 2011 4 4 Disassembly Gearbox Remove grease from gearbox Remove intermediate gear from gearbox housing Warning it is best to remove the large intermediate gear when the gear converter is in first gear Warning the intermediate gear with slipping clutch is only available as a complete spare part because the slipping clutch is pre set ...

Page 27: ... that switch the gears are slid up and are fixed or released by the balls depending on the gear selected Remove gear wheels and balls Remove control rod Dismantle small intermediate gear the two large gear wheels are slid up and are guided through the feather key the small gear wheel is press fitted The press fitting is damaged when the small gear wheel is disassembled The gear wheel and the shaft...

Page 28: ...r of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 4 Disassembly Gearbox Remove circlip from drill shaft gear wheel Press drill shaft out of gearbox housing using a press out sleeve remove gear wheel with feather key Tools outer circlip plier inner circlip plier ...

Page 29: ...ying and right of transfer is situated with FEIN Sahre MVK 05 2011 4 4 Disassembly Gearbox Loosen screw for securing shifting claw and remove shifting claw best done in first gear switch position Remove circlip for securing switching handle and remove switching handle Replace if necessary Tools outer circlip plier slotted screw driver ...

Page 30: ... Guide The disassembling of the gear box on a KBM 80 is very complex therefore the guide can be replaced without disassembling of the gear box too The way to do it you will see on the following pages Loosen the two screws on the guide and take it off Move the guide up and take it out of the drill jig Take off the gear rod Loosen the screws on the gliding bars and take it out together with the pres...

Page 31: ...ill jig Guide When mounting the gear rod on to the guide please watch that the locking pin is sitting on the lower end of the guide yellow circle The locking pin is a mechanical stop for the motor if you are working overhead to the ceiling When the guide has to be replaced please change the locking pin too every time Generally the condition of the locking pin has to be checked on every case of rep...

Page 32: ...such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 1 Assembly Drill jig Guide Put in the gliding bars to the drill jig and feed the screws not tighten Lay in the gear rod to the gear teeth of the gear box locking pin down yellow circle Move down the guide from the upper side Tools allen key 4 mm ...

Page 33: ...ion such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 1 Assembly Drill jig Guide Move up the gear rod with the gear teeth of the gear box until the screw holes match together Tighten the screws on the guide Put in the pressure bar and adjust the feed rate Tools allen key 5 mm allen key 3 mm ...

Page 34: ...This causes breakthrough detection to not respond and automatic withdrawal does not work as a result If a customer complains about the withdrawal function not working Loosen set screw slightly Knock dove tail guide out you can also knock the outer bearing Re tighten set screw from the middle out in small twists of 30 45 repeat process if necessary until drill motor is without play and spider can b...

Page 35: ...wer of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 2 Assembly Drill motor Insert field coil into motor housing To do this insert cables through motor housing Secure field coil with two screws Insert and screw down carbon holder Tool PH 2 cross tip screwdriver ...

Page 36: ...bly Drill motor Press fit ball bearing and magnet ring Attach spacer to bearing Attach armature to intermediate bearing and press in Insert assembled intermediate bearing in motor housing and secure with 4 screws Fill gearbox with grease 350 g 3 21 320 07 18 9 Stick the Gearbox with Loctite 5188 Close the Gearbox with the 4 screws Tool Grease 3 21 320 07 18 9 PH 2 cross tip screwdriver External ci...

Page 37: ...ion Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 2 Assembly Drill motor Insert and connect carbon brushes Fit both carbon brush covers Connect motor electronics and place in motor housing Tool PH 2 cross tip screwdriver Flat nose pliers ...

Page 38: ...s registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 2 Assembly Drill motor Attach plastic housing Insert protective hose with connection cables and lock Connect white speed cable and ribbon cable to console electronics ...

Page 39: ...h as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 2 Assembly Drill motor Insert console electronics into holder and attach rubber safety shutdown mat Secure plastic housing with 2 screws Attach and screw down cover warning check that pushbutton is secure it must not jam Tool PH 2 cross tip screwdriver ...

Page 40: ...opying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 3 Assembly Gearbox Insert switching handle and secure with circlip Place shifting claw in housing and move switching handle pin into guide Insert and tighten thread bolt best to do this in first gear switch position Tool Slotted screwdriver External circlip pliers ...

Page 41: ... right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Insert selector shaft into shaft Insert switch bar and fix with dowel pin Screw handles into switch bolts Warning replace cylinder pins and switch bar after every disassembly process because the press fitting is damaged during disassembly Tool Punch Steel hammer ...

Page 42: ...gistration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Insert ball spring and set screw Fix set screw manually must not compress solid otherwise automatic function will not work Tool Socket head wrench size 3 ...

Page 43: ...stration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Slide ball bearing on to shaft and press fit secure with circlip Insert balls slide on gear wheel spacer and secure with circlip Tool External circlip pliers ...

Page 44: ...case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Slide housing over bearing as far as stop by gently striking with the hammer Tool Plastic hammer ...

Page 45: ...ying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Complete feed motor with spacer ball bearing and worm wheel The worm wheel is secured to the feed motor shaft with a set screw The shaft has a milled groove on one side with which the set screw must come into contact Tool Socket head wrench size 3 ...

Page 46: ...ch as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 4 Assembly Feed unit Assemble feed motor and feed gearbox Warning the spacer is not fixed It must be in the recess and can easily slip out of place during assembly See arrow Screw motor down to gearbox with four screws Tool Socket head wrench size 3 ...

Page 47: ... Feed unit Fit pre assembled spider with feed motor on drill jig Insert feed motor cable through hole in drill jig do not bend cable too much otherwise it might break Insert guide bush Remove Loctite residue on threaded bar and nut and clean parts During assembly moisten threaded bar with Loctite 242 then tighten nut to 1 Nm Torque of 1 Nm must be complied with otherwise the automatic feed will no...

Page 48: ...pecially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 5 5 Assembly Electronics Tank Place bottom part of foam in drill jig Insert electronics in foam ...

Page 49: ...K 05 2011 Connect mains cable and motor cable Insert plug of magnetic foot Insert gearbox motor plug KBM 80 auto only Insert plug for magnetic field monitoring Remove circuit board s earth contact 5 5 Assembly Electronics Tank Warning to connect the mains cable and motor cable you must open the springs in the cable clamp with a small screwdriver in advance so you can then slide the cables in ...

Page 50: ...ituated with FEIN Sahre MVK 05 2011 Insert coolant pump hoses and distributor in foam cover Connect earthing conductor contact to coolant pump Insert motor cable through opening Attach foam cover and metal cover and screw down Warning do not jam any cables when attaching the two covers 5 5 Assembly Electronics Tank Tool Torx 20 screwdriver PH2 cross tip screwdriver ...

Page 51: ...pecially in case of industrial rights registration Any power of disposition such as copying and right of transfer is situated with FEIN Sahre MVK 05 2011 Place coolant tank on top guide yellow circle and then press down 5 5 Assembly Electronics Tank ...

Page 52: ...uated with FEIN Sahre MVK 05 2011 Plastic hammer Steel hammer Drive pin Slotted screw driver big small Allen key 2 3 4 5 mm Cross slotted screw driver PH 1 PH 2 Torx screw driver TX 20 Circlip plier inner outer Flat plier Ring wrench 13 mm Fork wrench 17 mm Tools All tools are available in normal retail FEIN Spezial tools various pulling off devices for ball bearings ...

Page 53: ...net switch flashing code Flashing code Frequency Possible fault regular slow 100ms ON 100ms OFF Magnet power too low regular fast 48ms ON 48ms OFF Magnet current too high Drill stand temperature too high long short 400ms ON 100ms OFF Magnet holding force reduced to 50 Electronic drill stand defective Magnet current too low magnet possibly defective communication error between drill stand and drill...

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