Service Manual D21580K
Contents
1. 0x25 50 which fasten the pair of handle halves 23 together Remove the two screws 4 55x32 57 which fix the upper half of handle to the motor housing 70 After taking off the upper half switch 5 anti interference capacitor line cord 3 and cable grommet 22 can be dismantled o Disconnect the printed circuit board 4 from switch 5 Remove the lower half of the handle Now exchange of the printed circuit board 4 is possible To do this disconnect the printed circuit board from stator 2 and release the two screws 4 0x12 72 o Put aside the brush holder covers 73 and take out the carbon brushes 74 After that lift the gear bearing shield 77 and the rotor 7 together out of motor housing o Remove the two screws M4x16 33 and pull out the rotor and the shaft seal 63 from the gear bearing shield o Now the rotor 7 can be checked and exchanged if it is necessary Take care of the bearings and the correct position of the blue bearing cap o To exchange the motor housing 70 or the field 2 carry out the following Disconnect the field 2 from the brush holders 75 Unscrew the brush holders from motor housing and put them aside Take the air guiding ring 77 out of the motor housing and pull out the field Service Manual D21580K o Note To remove the field from the fieldcase tap on the front of the fieldcase When reassembling tap on the rear 2 Gearing Section o Start dismantling the gearbox sect2. Service Manual D21580K Repair instructions for the diamond core drill D21580K l General DEWALT diamond core drills should only be repaired by authorized service centres The following explanations are in accordance with the spare parts list and service drawing for the D21580K a attempting service carry out the following Check condition of cord and plug Remove Tool bit Accessory Carry out an Earth continuity Earth leakage and Insulation test flash test where appropriate Never repair a product whilst it is plugged into a power supply Where fitted ensure side handles function correctly 3 x n n 4 5 wa WS ll Dismantling the diamond core drill 1 Motor Section o Ensure the unit is disconnected from the mains supply Remove the additional handle 67 Place the drill in the correct service fixture in a vertical position with motor at the top to avoid the run out of gear oil Remove the four screws 4 55x60 24 and pull the motor from the gearbox Pour the gear oil into a proper container and dispose of it if necessary using the correct procedures for the disposal of waste oil Dismantling of the motor can now start o Please Note If the motor section is not required to be dismantled for a repair then care should be taken as the gear bearing shield 7 will also pull out bringing the armature with it this will then require the brush covers to be removed to refit the brushes o Release the five screws 4
3. g press down until the clip snaps into place Replace the switch button 19 in the gearbox housing Put the gear block 31 on the spindle and mount the gear lever 20 by securing with the cap screw M5x30 29 Use loctite on the screw Test smooth running of the switch button and the actuating of the gear block Ensure the clutch 62 is correct Only use clutches matching the required torque setting values Furthermore the loose clutch parts have to slide smooth on the clutch shaft to guarantee the full functionality of the safety clutch After checking the clutch insert it into the needle bearing in the gearbox and refill the gearbox housing with the correct gear oil 180ml Check and replace if necessary the O ring 36 on the gear bearing shield 17 and join the gearbox to the motor using four screws 4 55x60 24 Ensure that the spindles line up with the bearings in the gear bearing shield 17 Replace the side handle 61 IV Checklist for testing the machine O O O O O Check for correct assembly Check the functionality of the machine first and second gear Test speed adjustment in different switch positions Test overload cut off Check isolation of machine with high voltage 1500V V Grease and Glue Product Where used 1 Gearbox Oil Lubcon Turmogearoil PE 150 180ml inside gearbox housing 18 2 Sealing Glue Silicone Omnivisc 1002 Between screw M4x16 32 and gear bearing shield 17 Fix LED i
4. ion by taking out the clutch complete 62 The torque of safety clutch must be set between 14 and 16 5 Nm A special service tool is used to determine the torque setting Do not reuse if the values are outside of this range o The 2 speed mode switch can now be removed Loosen the screw M5x30 29 and take off the gear lever 20 press out the switch button 79 Check rubber O ring 27 for damage o Now pull out the gear block 37 and remove the circlip 19 1 30 from spindle o Using the correct Service tooling press out the spindle 9 with ball bearing 6004 2RS 25 Now remove the ball bearing 6904 2RS 28 and the shaft seal 26 o Removal of the bearings 27 38 and 39 in the gearbox housing 78 and gear bearing shield 17 is done by warming of these metal parts lll Assembling the diamond core drill 1 Motor Section o Assembly starts with the motor housing 70 Press in the field 2 without trapping any wires and ensuring that they are routed correctly Screw on the brush holders 75 Connect the wires from field 2 and the brushes 74 to the brush holders 75 o Insert the air guiding ring 77 The notches on the ring must fit with the rips of motor housing o Using the correct service tooling press the shaft seal 63 grease lips liberally into the gear bearing shield 77 then press in the rotor complete 7 The rotor has to be locked using the two screws M4x16 32 with toothed locked washer 33 d
5. isc 34 and round ring 35 These have to be set in with silicone glue for sealing o Press the armature SA into the motor housing exactly The rotor should be free and move easily No wires must touch the rotor Replace the brushes 74 and brush holder covers 13 o Assemble the printed circuit board 4 to the motor housing Check the back side of the PCB for full covering with black protection layer Connect the printed circuit board with field and PTC resistor o Replace the lower half of the handle 23 replace the switch 5 with line cord 3 and cable grommet 22 Finish all electrical connections switch printed circuit board switch line cord see Wiring Diagram Ensure that all wires are routed correctly and there is no chance of trapping when the top half of the handle is secured o Complete the assembly of motor by securing the upper half of the handle Push the LED and holder into the hole of the handle Service Manual D21580K 2 Gearing Section O Start with gearbox housing 18 Apply a liberal amount of grease on the shaft seal 26 insert it into the gearbox housing using the correct service tooling Press the ball bearing 6004 2RS 25 onto the spindle 9 and press this SA into the gearbox Press ball bearing 6904 2RS 28 onto the spindle inside the gearbox housing Check that the spindle has not been pressed back out slightly Replace the cir clip 30 over the spindle and using the service toolin
6. n LED holder 52 3 Screw Glue Loctite Screws 29 Side handle 60 to adaptor 59 4 Seal Grease Rhenus Norlith LZP 2 Inside shaft seals 26 63
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