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3
2. Using a thin slotted screwdriver, release the tension on the Brush
Spring (25 or 35) and remove the two Brush Assemblies (24 or 33)
from the Rear End Plate (23 or 32).
3. Carefully pull the copper wires to remove the Brush Assemblies.
NOTICE
Be careful not to damage the wires.
If the Brush Assemblies need to be replaced, desolder the blue and
red Motor wires and remove the Brush Screws (26 or 34).
4. Using a thin blade screwdriver, remove the Motor Assembly
Springs (34 or 31) by inserting the screwdriver between the
Springs and the Rear End Plate and prying upward.
5. Remove the Front End Plate (33 or 24) from the Field (32 or 25).
6. Remove the Rear End Plate and the Motor Plate (27 or 30) by
inserting a slotted screwdriver into the space between the Rear
End Plate and the Field and prying upward.
7. While pushing the Rear Armature Bearing (28 or 29), pull the
Armature (31 or 26) from the Field.
NOTICE
Do not damage the commutator or windings on the Armature.
Hold the Armature body, not the commutator, when removing.
8. Remove the Push Rod (35 or 36) from the Armature.
9. Inspect the Push Rod. If it is worn, replace it.
10. Inspect the Rear Armature Bearing. If it does not rotate smoothly,
replace it.
11. Inspect the gear teeth on the Armature. If they are worn or
damaged, replace the Armature.
12. Inspect the front Armature Bearing. If it does not rotate smoothly,
replace the Armature.
13. Inspect the commutator, If it is worn, replace the Armature.
14. Clean the Armature, Field, Motor Plate and the End Plates using a
piece of fine cloth. For excess contamination, spray with contact
cleaner and brush if necessary.
Disassembly and Inspection of the Electronics
1. To remove the Trigger Switch (8 or 50), Reverse Switch (9 or 48)
or Brake Switch (15 or 42), remove any screws and pull the Switch
from the Housing. Desolder and remove the lead wires.
2. To remove the Insulator (71 or 49), desolder the lead wires.
Assembly
Assembly of the Electronics
NOTICE
Before soldering any wire, slip a piece of heat shrinkable tubing
over the wire.
1. To assemble the Electronic Components, resolder all wires to the
Insulator (71 or 49). Also resolder all wires to the Brake Switch
(15 or 42) and the Trigger Switch (8 or 50).
2. Reattach the Brake Switch to the Switch Plate (10 or 39) and
screw the Plate into the Housing (1 or 44).
3. Insert all electronic components into their proper locations.
Refer to Dwg. TPD1817 on page 13.
NOTICE
Be sure the notch in the Insulator fits with the tab in the Housing.
Assembly of the Motor
1. Carefully insert the gear end of the Armature (31 or 26) into the
notched side of the Field (32 or 25).
NOTICE
Be careful not to damage the commutator or windings.
2. Install the Front End Plate (33 or 24) onto the Field.
3. Place the Motor Plate (27 or 30) onto the Rear End Plate (23 or 32).
NOTICE
Be sure to install the Motor Plate correctly. The edge of the Motor
Plate must be parallel to the step in the Rear End Plate.
4. Push the Rear End Plate into the notches of the Fields.
5. Snap the Motor Assembly Spring (34 or 31) into notches of the
End Plates.
6. Insert the Brush Assembly (24 or 33) into the Rear End Plate. Be
careful not to twist or damage the copper wire.
NOTICE
Make sure the Brush Assembly is positioned correctly. The
connection point of the copper wire on the Brush Assembly
should be closer to the rear end than the front end of the Motor
Assembly.
7. Insert the Brush Spring (25 or 35) into the Rear End Plate. Using
a small screwdriver to tension the Spring, insert the end of the
Brush Spring into the notch on the End Plate.
8. Solder the blue and red Motor lead wires if the Brush Springs
were replaced. Refer to Dwg. TPD1814.
(Dwg. TPD1814)
9. Apply grease to both ends of the Push Rod (35 or 36) and insert it
into the center hole of the Motor Assembly.
Assembly of the Gear Case and Clutch Housing
1. Place the three Spindle Planet Gears (41 or 19) onto the Spindle
Assembly (40 or 18).
2. Place the three Gear Head Planet Gears (39 or 21) onto the Gear
Head Assembly (38 or 20).
3. Grease the gears.
4. Place the Gear Head Assembly onto the Spindle Assembly,
5. Grease both sides of the Thrust Washer (42) and place it on the
Spindle bearing.
6. Insert the Cam (43 or 16) into the Spindle Assembly.
7. While rotating the Gear Case (37 or 22) and holding the Cam,
insert all parts into the Gear Case.
8. Grease the Gear Case side of the Motor Clamp Spacer (36 or 23)
and insert the Motor Clamp Spacer into the Gear Case.
9. For Model EL1007, grease the notches on the Cam and place the
two Cam Pins (44) into the notches.
10. Grease the inside of the Bit Holder Assembly (48 or 12).
11. Insert the Cam Guide Sleeve (47 or 15) into the Bit Holder.
12. Grease the ball bearings under the spring support on the Bit
Holder Assembly.
13. Grease the holes on the Bit Holder and insert the two Cam Guide
Balls (49 or 14).
14. For Model EL1007, grease the inside of the Cam Collar (45) and
place it onto the Bit Holder.
15. For Model EL0109, grease the bottom end of the Bit Holder
Assembly and place the Cam Guide (13) onto the Bit Holder,
Grease the holes in the Cam Guide and insert the two Cam Guide
Balls.
Summary of Contents for EL 24V DC Series
Page 7: ...Notes...
