Form 16575318-Edition 1
3
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 Rear End Plate and prying upward.
5.
Remove the Font 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 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.
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 Field.
5.
Snap the motor Assembly Springs (34 or 31) into the 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 nd 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.
16. Fit the two notches at the rear of the Gear Case Assembly into the
Gear Case Fixture part no. EL0410B-J37.
17. Place the Bit Holder Assembly into the Gear Case.
18. Place the Clutch Spring (51 or 10) and the Clutch Spring
Plate (52 or 9) over the Bit holder.
19. Place the Clutch Housing (53 or 8) partially into the Gear Case.
NOTICE
This is a left hand thread.
At the middle of the Clutch housing threads apply Loctite ®* Thread
Locker 3 Bond 1406 to three of the threads. Screw the Clutch Hous-
ing all the way into the Gear Case.
20. Using an open end torque wrench, tighten the Clutch Housing to 20
Nm torque.
21. Install the Bit Retainer Retaining Ring (55 or 3) into the groove of the
bit Holder. Place the side with the sharp edge first.
22. Apply grease to the holes of the Bit Holder and insert the two Bit
Retaining Balls (50 or 11) into the Bit Holder.