SPECIAL TOOLS Core Drilling Machines -...
Transcript of SPECIAL TOOLS Core Drilling Machines -...
SPECIAL TOOLS
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Core Drilling Machines
SERVICE MANUAL
Torque WrenchRange: > 100 Nm (22 mm square drive type)For BCR164/6 & BCR300/12 safety clutch
Art. 6.512.098
Torque WrenchRange: 0-25 Nm. (19 mm square drive or socket head type)For BCR130/5BG & MG safety clutch
Art. 6.512.097
Necessary Tools for machine assemblyBEAST by BBTEC Core Drilling Machines
Soft Hammer (preferred plastic head)
Art. 6.512.096
Circlip Pliers for external retaining rings(10-25 mm)
Art. 6.512.099
Outside snap ring Circlip Pliers(15-60 mm, with special tips for snap-rings and spring-clips)
Art. 6.512.100
Circlip Pliers for internal retaining rings(straight, 19-60 mm)
Art. 6.512.101
Service Manual
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Blind Bearing Pullers / Split Collet Pullers(8-10.5 mm, 10.5-12.5 mm, 13-17 mm)
Art. 6.512.104
Bench Press Tool
Special Toolkit Case(see Service Manual Special Tools for use of each tool)
Bearing Puller Tool(0-40 mm)
Art. 6.512.102
Separator Tool(D max. > 50 mm)
Art. 6.512.103
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Service Manual
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Slide and …Slide the special tool on the drill spindle
LockLock the special tool with the gearbox to a vice
STEP 2
Special tool 08-170-162-01 to secure gear box with drill spindle to a vice
Service Manual – Special Tool 08-170-162-01BCR130/5BG & MG, BCR164/6, BCR300/12
08-170-162-01
STEP 1
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Service Manual – Special Tool 06-220-833BCR130/5BG & MG
Special tool 06-220-833 to assemble seals in BCR130/5BG & MG gear box
To assemble seals, position number 7, in gear box BCR130/5BG & MG, position number 23, see supported exploded view
Assembly parts• Gear box BCR130/5BG & MG
Part # 6.000.063• 2x Seals
Part # 6.502.013
Grease Apply silicon based grease to both seals
Grease and positionApply silicon based grease on the inside of the gear box.Position the first seal horizontally in the gear box with the open side upward.
STEP 1 STEP 2
06-220-833
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06-220-833
PressPress the seal using the special tool all the way down.
Second sealPosition the second seal horizontally in the gear box with the open side downward. Press the seal using the special tool down until the ring levels with the wider part of the gear box.
STEP 3
STEP 4
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Service Manual – Special Tool 06-220-836BCR130/5BG & MG
Special tool 06-220-836 to assemble seals in BCR130/5BG & MG gear box
To assemble seals, position number 16, to gear box BCR130/5BG & MG, position number 23, see supported exploded view
PositionPosition the seal with the open side downward on top of the special tool. Turn over and place the tool above the seal hole.
GreaseGrease the seal hole with silicon based grease
STEP 2STEP 1
Assembly parts• Gear box BCR130/5BG & MG, part # 6.000.063• 1x Seal, part # 6.502.014
06-220-836
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PressPress the the seal gently in the hole
STEP 3
06-220-836
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Special tool 06-220-837 to assemble ball bearings in BCR130/5BG & MG gearbox
To assemble ball bearing, position number 24, to gear box BCR130/5BG & MG, position number 23, see supported exploded view
Assembly parts• Gear box BCR130/5BG & MG
part # 6.000.063• Ball bearing part# 6.504.012
Grease and positionGrease the ball bearing hole with silicon based grease and position the bearing horizontally in the hole
Position tool and assemblePosition the special tool on the ball bearing. Tap with caution the bearing gently in place with a rubber hammer.
STEP 2
Service Manual – Special Tool 06-220-837BCR130/5BG & MG
06-220-837
STEP 1
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Assembly parts1 Gear spindle, part # 6.130.008 2 2x Washer, part # 6.130.0093 Bearing bush, part # 6.130.011 4 Gear wheel #2, part # 6.130.010 5 Ring, part # 6.130.0126 Spring washer, part # 6.505.017 7 Nut, part # 6.503.004
Used oil, cleaner and glue• Shell Spirax AX 80W-90• Würth saBesto IndustrieClean, part # 0893 140-E or
Loctite 7235 Nettoyant/Reiniger, part # 35953• ThreeBond 1374 glue
Service Manual – Special Tool 12-170-100-1 / 09-120-002-01 BCR130/5BG & MG
Special tools 12-170-100-1 and 09-120-002-01 for BCR130/5BG & MG safety clutch
• For fastening and adjusting the nut with a torque wrench
• To assemble a BCR130/5BG & MG safety clutch
Lock and mountLock the special tool in a vice and mount the gear spindle (1)
OilBrush oil on the gear wheel
MountMount the first washer (2)
STEP 3
12-170-100-1 / 09-120-002-01
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5
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1 2
STEP 2STEP 1
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OilBrush oil on the washer (2)
OilBrush oil on the washer (2)
OilBrush oil on the gear wheel (4)
MountMount the bearing bush (3)
MountMount the second washer (2)
MountMount ring (5)
CleanClean nut thread of gear spindle oil free
GlueGlue thread of nut (7) with Three-Bond 1374
MountMount the nut (7)
MountMount spring washer (6)
SecureSecure ring (5) in correct place
MountMount gear wheel #2 (4)
STEP 15
STEP 12STEP 11
STEP 6
12-170-100-1 / 09-120-002-01
STEP 4 STEP 5
STEP 7 STEP 8 STEP 9
STEP 10
STEP 13 STEP 14
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FastenFasten the nut (7) with a torque wrench hand tight
Mount toolMount the special tool
FastenFasten the special tool with a torque wrench to 16/17 Nm
AdjustNow repeat Step 15, 16 and 17 by loosening or fastening the nut (7) until the safety clutch slips with the torque wrench set to 16/17 Nm
STEP 19
12-170-100-1 / 09-120-002-01
STEP 18STEP 17STEP 16
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Special tool 06-220-835 to assemble seals and ball bearings in BCR130/5BG & MG motor cover
To assemble seal, position number 35, and ball bearing position number 36, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view
Assembly parts• Motor cover BCR130/5BG & MG, part # 6.130.013• 1x Ball bearing, part # 6.504.021• 1x Seal, part # 6.502.021
GreaseGrease the seal hole with silicon based grease
Position toolPosition the special tool on top of the seal
Position sealPosition the seal horizontally in the seal hole with open side down-ward
STEP 3STEP 2
Service Manual – Special Tool 06-220-835BCR130/5BG & MG
06-220-835
STEP 1
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Grease and positionGrease the ball bearing hole with silicon based grease and position the bearing
Press 2Turn over the special tool and center position the tool on top of the seal. Press the seal a second time.
Position tool, pressPosition the special tool on top of the ball bearing. Press the bearing in place.
Press 1Press the seal in place
06-220-835
STEP 5
STEP 6
STEP 7
STEP 4
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Special tool 06-220-834 to assemble needle- bearings in BCR130/5BG & MG motor cover
To assemble needle-berarings, position number 21, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view
Assembly parts• Motor cover BCR130/5BG & MG
part # 6.130.013• 2x Needle-bearings
part # 6.504.011
Grease and positionGrease both bearing holes with silicon based grease. Position the needle-bearings horizontally in the holes with shown text down.
Press 1Press both needle-bearings in the holes
Position tool and press 2Position the special tool and press the needle-bearings one by one in place
STEP 3
Service Manual – Special Tool 06-220-834BCR130/5BG & MG
06-220-834
STEP 2
STEP 1
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08-170-165-01
Special tool 01-100-114-1 for BCR164/6 safety clutch
For fastening a BCR164/6 assembled safety clutch with a torque wrench
LockLock the special tool in a vice
PositionPosition the BCR164/6 assembled safety clutch in the special tool
SecureTighten the nut with a torque wrench to 9 kN/90 Nm. Attention: left handed thread
STEP 3
Service Manual – Special Tool 01-100-114-1BCR164/6
CCW
STEP 1
STEP 2
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Service Manual – Special Tool 08-170-165-01BCR164/6
08-170-165-01
Special tool 08-170-165-01 to support the fan when assembling to BCR164/6 armature
To support the fan, position number 38, when assembling to the BCR164/6 armature, position number 37, see supported exploded views
Assembly parts• Armature , part # 6.513.098• Fan, part # 6.513.099
Position Position the fan on top of the special tool with the metal ridge downward
Grease Lightly grease the the fan connect-ing part of the armature
Mount Mount the armature on top of the fan. You are now ready to press.
Press Press the armature on the fan in a straight upright position step by step while rotating the tool
STEP 4
STEP 3
STEP 2STEP 1
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Service Manual – Special Tool 98-0090-02HBCR164/6 / BCR300/12
98-0090-02H
Special tool 98-0090-02H to mount seals in the BCR164/6 or BCR300/12 water bush
To assemble 2x seals in water bush, BCR164/6: seals position number 55 water bush, position number 54 BCR300/12: seals position number 19 water bush, position number 18See supported exploded viewsAssembly parts
• 2x Seals, part # 6.502.1251. Water bush BCR164/6, part # 6.164.0402. Water bush BCR300/12, part # 6.250.020
Grease Apply silicon based grease inside the water bush
Put on seal 1Put the first seal on the long end of the special tool with the open side upward
Position tool Positon the tool over the water bush. Keep the ridge on the water bush to the bottom.
STEP 1 STEP 2 STEP 3
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98-0090-02H
Press Press the seal in the water bush all the way down
Attention!Mount the lock ring, position number 56 on the supported exploded view
Position and press Positon the tool over the water bush. Press the second seal in the water bush.
Put on seal 2Put the second seal on the short end of the special tool with the open side downward
STEP 6STEP 5STEP 4
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STEP 3
Special tool 98-0090-02G for BCR300/12 safety clutch
For fastening a BCR300/12 assembled safety clutch with a torque wrench
Service Manual – Special Tool 98-0090-02GBCR300/12
LockLock the special tool in a vice
PositionPosition the BCR300/12 assembled safety clutch in the special tool
SecureTighten the nut with a torque wrench to 9 kN/90 Nm. Attention: right handed thread
01-100-114-1
CW
STEP 1
STEP 2
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98-0090-02G
GreaseGrease both bearing holes with silicon based grease
Slide and lockSlide the special tool on the drill spindle and lock the tool to a vice
Position toolPosition the special tool on top of the bearing
Assemble Tap with caution the bearing gently in place with a rubber hammer.
Position bearing 1Position a ball bearing horizontally in place
Assembly parts• Gear box BCR300/12
part # 6.000.060• 2x Ball bearings
part # 6.504.060
Special tool 08-170-161-01 to assemble ball bearings in BCR300/12 gearbox with drill spindle
To assemble ball bearings, position number 32, to gear box BCR300/12, position number 7, see supported exploded view
Special tool 08-170-162-01 to secure gear box with drill spindle to a vice
Service Manual – Special Tool 08-170-161-01 / 08-170-162-01 BCR300/121
STEP 4STEP 3STEP 3
STEP 1 STEP 2
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Position toolPosition the special tool on top of the second bearing
Assemble Tap with caution the second bearing gently in place with the rubber hammer.
Position bearing 2Position the second ball bearing horizontally in place
STEP 7STEP 5
08-170-161-01 / 08-170-162-01
STEP 6
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08-170-161-01 / 08-170-162-01
Position lock ring
Mount lock nut
• Gear box BCR300/12 part # 6.000.060• Lock ring part # 6.505.090• Lock nut part # 6.503.070
Special tool 08-170-162-01 to secure gear box with drill spindle to a vice
Special tool 98-0090-02F to secure the drill spindle to BCR300/12 gearbox
To secure lock ring, position number 5, and lock nut, position number 4, for gear spindle to gear box BCR300/12, position number 7, see supported exploded view
Assembly parts
Service Manual – Special Tool 08-170-162-01 / 98-0090-02F BCR300/12
Slide and lockSlide the special tool on the drill spindle and lock the tool to a vice. ATTENTION: Be sure the ball bear-ings position number 32, part # 6.504.060 are first mounted according sheet 1 .
STEP 1 STEP 2
STEP 3
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Position toolPosition the special tool over the drill spindle on the lock nut in such way that the tool tabs fits into the nut slots
Tighten nutSecure the lock nut hand tight
Position nutWhen tightened, position the lock nut in such way that one of the nut slots is above a lip of the lock ring
Bend lipBend the lip of the lock ring with a screwdriver into a positioned nut slot
STEP 4
STEP 5
STEP 6 STEP 7
08-170-162-01 / 98-0090-02F
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