DeWalt D25900K Bedienungsanleitung

Page 1of 63

Full Strip down and Re-assembly procedure for the 10KG Demolition Hammer

D25900K.

This procedure is in Four main sections.

1. General Information / Tooling

2. Total Strip Down.

3. Re-assembly.

4. Routine Servicing.

Tool Holder

Anti-Vibration

Unit

Gearbox

Motor Unit

Crankcase

Piston &Cylinder

Beat Piece & Ram

Switch

Page 2of 63

INDEX.

Page 3 General Information.

Page 4 Service Kits

Page 5 Hand Tools Required

Page 6-8 Service Tooling.

Dismantle

Page 9-10 Remove Tool Holder and Beat Piece.

Page 11-15 Tool Holder Assembly.

Page 16-17 Anti-Vibration Unit.

Page 18-25 Motor and Gearbox unit .

Re-assembly

Page 26-29 Gearbox and Crankshaft.

Page 30-33 Motor unit.

Page 34-36 Crankcase, Piston and Gear Case.

Page 36-39 Switch / Handle

Page 40-41 Cylinder and Ram.

Page 42-44 Anti-Vibration unit.

Page 45 SDS Spindle.

Page 46-47 Spindle & Flange

Page 48-50 Turning Sleeve.

Page 51-52 Tool Bit Locking assembly.

Page 53-57 Sliding Sleeve / Snap Ring.

Page 58-59 Beat Piece.

Page 60-61 Tool Holder SA to Product.

Routine Servicing

Page 62 Servicing.

Page 63 Fault Finding and Test Data.

Page 3of 63

SECTION ONE.

General Information.

qONLY THE CORRECT GREASE MUST BE USED

qWhen repairing this product it is very important to keep the working area clean and free

from any dust or debris.

If any contamination is allowed within the Tool holder, Anti-vibration unit or Gear Box this

will cause premature failure of the Product.

qIf significant wear has occurred within in the Tool Holder components then it is

recommended to replace the complete unit (111).

qIf ANY of the O Rings are disturbed when dismantling, they must be replaced.

qIf only the Motor/Switch needs attention, it is not necessary to remove the Anti-Vibration &

Tool Holder units, although it can make the operation difficult if left attached, because of

the size and weight of the product.

If they are removed then the following should be noted

qOnly undo the 4 Screws (65) from the Anti-Vibration Unit and remove the complete front

assembly including the Tool Holder Unit from the Motor Housing.

qThe Piston, Crank Case, Cylinder & Anti-Vibration Unit will be exposed and should be

kept covered to prevent any ingress of dust or debris.

qThe O Ring’s (49) Piston and (79) Housing must be replaced on re-assembly.

Serial Number / Date Code.

A serial number and the Date code will be printed on the Main Metal Housing on the right

hand side next to the Anti-Vibration Unit. .

The Serial Number must be quoted on all repair documentation.

After repair, mark the housing next to the serial number with the letter ‘R’.

Page 4of 63

Service Kits.

Four Service kits will be available that contain all the O Rings, Grease, Brushes, Snap Rings,

Seals that are required when Servicing.

The first service kit is used when the unit comes in for its first brush change after 250 hours.

The Major Kit is used when the unit requires a complete strip down and rebuild.

First Service Kit 115 Volt. First Service Kit 240Volt.

Item No Part number Qty. Item No Part Number Qty

8487340-01 2 8 487340-00 2

49 487213-00 1 49 487213-00 1

73 487297-00 1 73 487297-00 1

77 487296-00 1 77 487296-00 1

79 323711-44 1 79 323711-44 1

87 487238-00 1 87 487238-00 1

88 487205-00 1 88 487205-00 1

89 487241-00 1 89 487241-00 1

104 323711-40 1 104 323711-40 1

108 487243-00 1 108 487243-00 1

109 487299-00 1 109 487299-00 1

800 578970-02 1 800 578970-02 1

Major Service Kit 115 Volt.Major Service Kit 230 Volt.

Item No Part number Qty. Item No Part Number Qty

8487340-01 2 8 487340-01 2

32 487224-00 1 32 487224-00 1

36 487209-00 1 36 487209-00 1

49 487213-00 1 49 487213-00 1

52 323711-42 1 52 323711-42 1

58 324007-11 4 58 324007-11 4

69 487288-00 1 69 487288-00 1

71 487298-00 1 71 487298-00 1

73 487297-00 1 73 487297-00 1

74 323711-41 2 74 323711-41 2

77 487296-00 1 77 487296-00 1

79 323711-44 1 79 323711-44 1

87 487238-00 1 87 487238-00 1

88 487205-00 1 88 487205-00 1

89 487241-00 1 89 487241-00 1

90 487244-00 1 90 487244-00 1

104 323711-40 1 104 323711-40 1

108 487243-00 1 108 487243-00 1

109 487299-00 1 109 487299-00 1

800 578970-02 1 800 578970-02 1

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Hand Tools required.

Soft faced mallet.

T Handled Torx Screw Drivers. TX10. TX15. TX20.

Long Nose pliers.

Torque wrench. ½ in Drive.

Torque Screwdriver.

Allen Keys. Size various

Circlip Pliers. Internal, External.

Press.

Vice.

Two legged puller.

Page 6of 63

Service tooling

559617-99 Crank Gear Removal & Assembly Tool.

Used to fit Double Gear ( 42 ) in conjunction with a Press.

Will remove and replace the crank gear ( 43 ) in conjunction with a Torque

Wrench

Used to fit Armature Seal (36) & Bearing (35) in conjunction with Service

Tool 559621-99.

559618-99 Motor assembly Tool.

Used to fit Motor Pot ( 2 ) & Armature ( 1 )

Page 7of 63

559621-99 Armature Seal & Bearing assembly Tool.

Used to fit Seal (36) & Bearing (35)

559620-99 Spindle Seal & Tool Holder assembly Tool.

Used to fit Seal (108) & Spring Guide (98)

Page 8of 63

559619-99 Snap Ring assembly Tool.

Used to remove and fit Snap Ring (88).

Page 9of 63

SECTION TWO

Remove Tool Holder and Beat Piece.

qRemove Side handle (59) if fitted.

qUndo six screws (102) remove Tool Holder Assembly (111) a flat bladed

screwdriver may be required to Gently lever the housing away from the

Anti-vibration unit.

qBeware that the internal components will fall out from the Tool Holder

qRemove item (72) from inside the Housing.

qRemove the O Ring

qRemove items (67,68,69,70). From inside the Tool Holder Unit,

Page 10 of 63

qRemove Beat Piece Bearing item (110) from Spindle (107) (this may be tight),

qRemove O Ring (109).

qPull off Rubber Seal item (87). From end of Tool Holder Unit.

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