Fein ABOP 10, Repair Instructions

Page 1: ...10 13 2 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 1 69 Version 1 Repair instructions ...

Page 2: ...ation FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 2 69 Version 1 1 Models described 2 Technical data 3 Provisions 4 Tools required 5 Lubricants and auxiliary substances required 6 Disassembly 7 Assembly 8 Troubleshooting 9 Connection diagram Contents ...

Page 3: ...strial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 3 69 Version 1 These instructions describe how to repair the following models Model Order no ABOP 6 710501 ABOP 10 710502 ABOP 13 2 710503 1 Models described ...

Page 4: ...ta The complete technical data can be found in the operating instructions for the model Test data Up to date test data for all models can be found on the FEIN Extranet Customer Service Repair Guides Lubricants The lubricants and container sizes available from FEIN can be found on the FEIN Extranet Customer Service Repair Guides Lists of spare parts Lists of spare parts and exploded views are avail...

Page 5: ...checked by a trained electrician as improper repair can result in serious risks to the user The provisions set out in DIN VDE 0701 0702 should be observed after repairs Only use original FEIN spare parts The relevant accident prevention regulations of the employers liability insurance associations are to be observed when commissioning The German Equipment and Product Safety Act applies for correct...

Page 6: ... gauge Cable hooks Circlip pliers Special tools Unlocking tool Arbor Sleeve Inner diameter 55 mm Outer diameter 65 mm Sleeve Inner diameter 15 mm Outer diameter 25 mm Sleeve Inner diameter 7 mm Outer diameter 30 mm Ball bearing support 19 mm Ball bearing puller 15 mm 6 41 07 015 00 0 Ball bearing puller 19 mm 6 41 07 019 00 7 Drawing off socket cap 6 41 04 150 00 8 Open ended spanner 17 mm width 4...

Page 7: ...ns all rights of disposal such as copying and circulation C SC_CSSM 2012 08 7 69 Version 1 4 Tools required Special tools Unlocking tool FEIN recommends using this unlocking tool because it is designed precisely for the plug contact used Order no 1 1579007 6 not available from FEIN Manufacturers www te com ...

Page 8: ...8 69 Version 1 5 Lubricants and auxiliary substances required Lubricants ABOP 6 Grease 0 40 101 0100 4 12 g Gearbox ABOP 10 Grease 0 40 101 0100 4 12 g Gearbox Grease 0 40 205 0000 2 Bearing journal of spur gear shaft ABOP 13 2 Grease 0 40 101 0100 4 25 g Gearbox Grease 0 40 205 0000 2 Bearing journal of spur gear shaft Sealants ABOP 6 10 13 2 Surface seal Loctite 5188 Gearbox head ...

Page 9: ...rights of disposal such as copying and circulation C SC_CSSM 2012 08 9 69 Version 1 6 Disassembly 1 Remove battery 2 Clamp socket wrench in drill chuck 3 Firmly hold drill shaft with open ended spanner 4 Unscrew drill chuck with socket wrench Tool Open ended spanner 17 mm width 4 mm 6 29 03 002 00 9 Socket wrench ...

Page 10: ...pecially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 10 69 Version 1 6 Disassembly 1 Remove screws from gearbox head 2 Remove gearbox head Tool Torx 20 screwdriver ...

Page 11: ... rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 11 69 Version 1 1 Loosen screws on upper housing section and remove this section 2 Remove clamping piece from lower housing section 6 Disassembly Tool Torx 15 screwdriver ...

Page 12: ...08 12 69 Version 1 1 Remove plug on motor 2 Pull shrink fit hose slightly to the right and press out individual cables over fixing mechanism on air guide ring 3 Press motor cable out of plug with unlocking tool NOTE The locking noses in the plug are worn during disassembly Use new plugs for assembly 4 Take motor and air guide ring out of housing 6 Disassembly Tool Unlocking tool ...

Page 13: ...N especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 13 69 Version 1 1 Press switch cable out of plug with unlocking tool 6 Disassembly Tool Unlocking tool ...

Page 14: ...e of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 14 69 Version 1 6 Disassembly Tool Ball bearing puller 19 mm Drawing off socket cap with tip 1 Pull ball bearing and sealing ring off motor ...

Page 15: ...l rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 15 69 Version 1 6 Disassembly ABOP 6 ABOP 10 ABOP 13 2 ...

Page 16: ...sal such as copying and circulation C SC_CSSM 2012 08 16 69 Version 1 1 Prise intermediate bearing off gearbox head 2 Pull out ball bearing 3 Dismantle circlip 4 Remove spur gear along with spring washer 6 Disassembly ABOP 6 Tool Ball bearing puller 6 41 07 015 00 0 Drawing off socket cap with tip 6 41 04 150 00 8 Circlip pliers ...

Page 17: ...of disposal such as copying and circulation C SC_CSSM 2012 08 17 69 Version 1 1 Remove clutch ring and rollers 2 Dismantle circlip 3 Press shaft out of gearbox head along with ball bearing 4 Take plastic washer off shaft 6 Disassembly ABOP 6 Tool Circlip pliers Arbor press Sleeve Inner diameter 30 mm Outer diameter 40 mm ...

Page 18: ...hts registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 18 69 Version 1 1 Dismantle circlip 2 Press ball bearing down and off shaft 6 Disassembly ABOP 6 Tool Circlip pliers Arbor press Sleeve Inner diameter 13 mm Outer diameter 17 mm ...

Page 19: ...such as copying and circulation C SC_CSSM 2012 08 19 69 Version 1 1 Prise intermediate bearing off gearbox head 2 Pull out ball bearing 3 Dismantle circlip 4 Drive out intermediate gear shaft 6 Disassembly ABOP 10 Tool Ball bearing puller 6 41 07 015 00 0 Drawing off socket cap with tip 6 41 04 150 00 8 Circlip pliers Plastic hammer ...

Page 20: ...dustrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 20 69 Version 1 1 Remove spur gear along with spring washer 2 Remove clutch ring and rollers 3 Dismantle circlip 6 Disassembly ABOP 10 Tool Circlip pliers ...

Page 21: ...ains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 21 69 Version 1 1 Press shaft out of gearbox head along with ball bearing 2 Take plastic washer off shaft 3 Dismantle circlip 6 Disassembly ABOP 10 Tool Arbor press Sleeve Inner diameter 30 mm Outer diameter 40 mm Circlip pliers ...

Page 22: ...s registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 22 69 Version 1 1 Press ball bearing down and off shaft 2 Press gear wheel down and off shaft 6 Disassembly ABOP 10 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 30 mm ...

Page 23: ...trial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 23 69 Version 1 1 Prise intermediate bearing off gearbox head 2 Drive out shafts 3 Remove shafts along with washers 6 Disassembly ABOP 13 2 Tool Plastic hammer ...

Page 24: ...M 2012 08 24 69 Version 1 1 Remove plate 2 Pull off switch pushbutton WARNING Parts may jump out When levering hold hand over leaf springs 3 Prise leaf springs opposite switch pushbutton out slightly 4 Prise up leaf spring on switch pushbutton side 5 Remove leaf springs metal bolts and switch bolt 6 Disassembly ABOP 13 2 Tool Combination pliers Medium slotted screwdriver ...

Page 25: ...ains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 25 69 Version 1 1 Pull out ball bearing 2 Dismantle circlip 3 Remove gear wheel and spring washer 6 Disassembly ABOP 13 2 Tool Ball bearing puller 6 41 07 015 00 0 Drawing off socket cap with tip 6 41 04 150 00 8 Circlip pliers ...

Page 26: ...ghts registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 26 69 Version 1 1 Remove clutch ring and rollers 2 Pull ball bearing out of gearbox head 3 Dismantle circlip 6 Disassembly ABOP 13 2 Tool Internal puller device Circlip pliers ...

Page 27: ...tration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 27 69 Version 1 1 Press shaft out of gearbox head along with ball bearing 2 Take plastic washer off shaft 6 Disassembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 30 mm Outer diameter 40 mm ...

Page 28: ...trial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 28 69 Version 1 1 Press ball bearing down and off shaft 6 Disassembly ABOP 13 2 Tool Circlip pliers Arbor press Sleeve Inner diameter 13 mm Outer diameter 17 mm ...

Page 29: ...l rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 29 69 Version 1 1 Pull out ball bearing 2 Press gear wheel down and off shaft 6 Disassembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 30 mm ...

Page 30: ...of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 30 69 Version 1 1 Press gear wheel down and off shaft 6 Disassembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 30 mm ...

Page 31: ...ustrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 31 69 Version 1 1 Dismantle circlip 2 Pull out draw key 3 Take off washer 4 Take gear wheels and balls off drive 6 Disassembly ABOP 13 2 Tool Circlip pliers ...

Page 32: ...P 6 10 13 2 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 32 69 Version 1 7 Assembly ...

Page 33: ...etains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 33 69 Version 1 WARNING Incorrect assembly will damage the device Motor shaft must be supported when pressing e g using an arbor 1 Press ball bearing on to motor 7 Assembly Tool Arbor press Arbor Ball bearing support D 19 mm ...

Page 34: ...ch as copying and circulation C SC_CSSM 2012 08 34 69 Version 1 WARNING Incorrect assembly will damage device Motor shaft must be supported when pressing e g using an arbor 1 Slide sealing ring on to motor shaft 2 Carefully press sealing ring on to motor 7 Assembly Tool Arbor press Arbor Sleeve Inner diameter 7 mm Outer diameter 30 mm ...

Page 35: ...ch as copying and circulation C SC_CSSM 2012 08 35 69 Version 1 1 Press bearing on to shaft 2 Fit circlip NOTE Use a new circlip for assembly 3 Slide plastic washer on to shaft NOTE The flat side of the plastic washer must be on the side of the bearing 7 Assembly ABOP 6 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 18 mm ...

Page 36: ...rial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 36 69 Version 1 1 Press shaft in to gearbox head 2 Fit circlip 7 Assembly ABOP 6 Tool Arbor press Sleeve Inner diameter 20 mm Outer diameter 27 mm Circlip pliers ...

Page 37: ...pecially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 37 69 Version 1 1 Slide clutch ring on to shaft 2 Insert rollers in clutch ring 7 Assembly ABOP 6 Right Wrong ...

Page 38: ...l rights of disposal such as copying and circulation C SC_CSSM 2012 08 38 69 Version 1 1 Slide spring washer on to shaft 2 Insert spur gear 3 Fit circlip NOTE Use a new circlip for assembly 4 Press bearing as far as stop on shaft 7 Assembly ABOP 6 Tool Arbor press Sleeve Inner diameter 6 mm Outer diameter 20 mm ...

Page 39: ...gistration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 39 69 Version 1 7 Assembly ABOP 6 1 Fill gearbox with grease 12 g 2 Apply Loctite 5188 surface sealant 3 Fit intermediate bearing on to gearbox head Tool Grease 0 40 101 0100 4 Loctite 5188 ...

Page 40: ...h as copying and circulation C SC_CSSM 2012 08 40 69 Version 1 1 Press bearing on to shaft 2 Fit circlip NOTE Use a new circlip for assembly 3 Slide plastic washer on to shaft NOTE The flat side of the plastic washer must be on the side of the bearing 7 Assembly ABOP 10 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 15 mm ...

Page 41: ... industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 41 69 Version 1 1 Press shaft in to gearbox head 2 Fit circlip 7 Assembly ABOP 10 Tool Arbor press Sleeve Inner diameter 20 mm Outer diameter 27 mm ...

Page 42: ...al rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 42 69 Version 1 1 Press gear wheel on to shaft 2 Press bearing in to gearbox head 7 Assembly ABOP 10 Tool Arbor press Sleeve Inner diameter 6 mm Outer diameter 20 mm ...

Page 43: ...pecially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 43 69 Version 1 1 Slide clutch ring on to shaft 2 Insert rollers in clutch ring 7 Assembly ABOP 10 Right Wrong ...

Page 44: ... all rights of disposal such as copying and circulation C SC_CSSM 2012 08 44 69 Version 1 1 Slide spring washer on to shaft 2 Insert spur gear 3 Fit circlip NOTE Use a new circlip for assembly 4 Press shaft in to gearbox head 7 Assembly ABOP 10 Tool Arbor press Sleeve Inner diameter 6 mm Outer diameter 20 mm ...

Page 45: ...registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 45 69 Version 1 1 Place washer on intermediate gear shaft 2 Press ball bearing as far as stop on shaft 7 Assembly ABOP 10 Tool Arbor press Sleeve Inner diameter 6 mm Outer diameter 20 mm ...

Page 46: ...gistration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 46 69 Version 1 1 Fill gearbox with grease 12 g 2 Apply Loctite 5188 surface sealant 3 Fit intermediate bearing on to gearbox head Tool Grease 0 40 101 0100 4 Loctite 5188 7 Assembly ABOP 10 ...

Page 47: ...l rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 47 69 Version 1 1 Press gear wheel on to shaft 2 Press bearing in to gearbox head 7 Assembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 30 mm ...

Page 48: ...rial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 48 69 Version 1 1 Press gear wheel on to shaft 2 Press bearing on to shaft 7 Assembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 30 mm ...

Page 49: ... as copying and circulation C SC_CSSM 2012 08 49 69 Version 1 1 Press bearing on to shaft 2 Fit circlip NOTE Use a new circlip for assembly 3 Slide plastic washer on to shaft NOTE The flat side of the plastic washer must be on the side of the bearing 7 Assembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 12 mm Outer diameter 15 mm ...

Page 50: ...industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 50 69 Version 1 1 Press shaft in to gearbox head 2 Fit circlip 7 Assembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter 20 mm Outer diameter 27 mm ...

Page 51: ...cially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 51 69 Version 1 1 Insert clutch ring 2 Insert rollers in clutch ring 7 Assembly ABOP 13 2 Tool Forceps Right Wrong ...

Page 52: ...as copying and circulation C SC_CSSM 2012 08 52 69 Version 1 1 Coat recesses for the draw keys in the guide sleeve with a little grease 2 Slide sleeve a little in to guide sleeve 3 Insert draw keys in guide sleeve 4 Slide sleeve fully in to guide sleeve The draw keys cannot now fall out 7 Assembly ABOP 13 2 Tool Small slotted screwdriver ...

Page 53: ...l rights of disposal such as copying and circulation C SC_CSSM 2012 08 53 69 Version 1 1 Lubricate the drive holes with a little grease 2 Insert balls in holes 3 Slide gear wheels on to drive NOTE The recesses in the gear wheels must be in line with the balls 4 Place washer on top gear wheel 7 Assembly ABOP 13 2 ...

Page 54: ...on FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 54 69 Version 1 1 Fit circlip 2 Insert draw key in drive 3 Press draw keys outwards The drive can then be easily placed on the drill shaft 7 Assembly ABOP 13 2 Tool Small slotted screwdriver Circlip pliers ...

Page 55: ... disposal such as copying and circulation C SC_CSSM 2012 08 55 69 Version 1 1 Insert spring washer 2 Insert gear wheel with drive Turn drive s gear wheel until cams of gear wheel sit in recesses in the clutch ring The gear wheel must slide down a little 3 Insert both shafts together 4 Fit both washers 7 Assembly ABOP 13 2 ...

Page 56: ...6 69 Version 1 1 Fit conical sleeve to drill shaft 2 Fit circlip to conical sleeve 3 Fit pull on taper on circlip 4 Apply pressure and press down pull on taper 5 Check that circlip is seated correctly in the drill shaft groove NOTE If the circlip isn t seated correctly in the groove the gear changeover won t work 7 Assembly ABOP 13 2 Tool Conical sleeve and pull on taper 64131017000 ...

Page 57: ...M 2012 08 57 69 Version 1 1 Insert plastic bolt as shown 2 Insert right hand metal bolt half way in to right hand hole 3 Insert both leaf springs in right hand metal bolt and in groove of guide sleeve of drive 4 Turn plastic bolt to the right and insert leaf spring in groove of plastic bolt 5 Insert left hand metal bolt in hole along with leaf spring 7 Assembly ABOP 13 2 ...

Page 58: ...N retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 58 69 Version 1 1 Insert switch pushbutton 2 Insert plate 3 Press ball bearing on to shaft 4 Test gear changeover before further assembly 7 Assembly ABOP 13 2 Tool Arbor press Sleeve Inner diameter mm Outer diameter mm ...

Page 59: ...istration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 59 69 Version 1 1 Fill gearbox with grease 25 g 2 Apply Loctite 5188 surface sealant 3 Fit intermediate bearing on to gearbox head 7 Assembly ABOP 13 2 Tool Grease 0 40 101 0100 4 Loctite 5188 ...

Page 60: ...pying and circulation C SC_CSSM 2012 08 60 69 Version 1 1 Check springs of battery plug contacts If necessary press the spring up a little 2 Fit air guide ring on to motor NOTE The recess with the detent must be next to the plug connection on the motor 3 Press motor cable in to air guide ring s guides 7 Assembly Tool Small slotted screwdriver ...

Page 61: ... Version 1 1 Insert motor in to lower section of housing with air guide ring 2 Insert black motor cable at bottom 3 Insert switch in to lower section of housing Place thin cables on top of black cable The red cable is at the top NOTE The thin cables must be under a thick cable so they are not squashed by the upper section of housing 7 Assembly Tool Small slotted screwdriver Cable hooks ...

Page 62: ...uch as copying and circulation C SC_CSSM 2012 08 62 69 Version 1 1 Insert cables in plug as shown Check whether cables are secure in the plug 2 Individually press motor plug s cables over fixing mechanism on air guide ring 3 Insert plug in motor 4 Insert red motor cable in the guide above the other cables 7 Assembly Tool Cable hooks ...

Page 63: ...all rights of disposal such as copying and circulation C SC_CSSM 2012 08 63 69 Version 1 1 Insert clamping piece in lower section of housing NOTE The same switch is also used by tools with potentiometer electronics e g ASCS 4 8 6 3 The small switch plug on this tool has no function and no connection 7 Assembly ...

Page 64: ...e of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 64 69 Version 1 Tool Torx 20 screwdriver 1 Fit upper section of housing and screw in place 2 Fit gearbox head and screw in place 7 Assembly ...

Page 65: ...uch as copying and circulation C SC_CSSM 2012 08 65 69 Version 1 7 Assembly 1 Fit drill chuck and screw in place 2 Clamp socket wrench in drill chuck 3 Firmly hold drill shaft with open ended spanner 4 Screw down drill chuck Tightening torque 35 Nm Tool Open ended spanner 17 mm width 4 mm 6 29 03 002 00 9 Socket wrench Torque wrench ...

Page 66: ...s with test board Battery plug contacts have come loose Check components Motor is running out of round Speed fluctuates Bearing gearbox is defective Check components Motor only turning in one direction Plug on motor has come loose or is not secure Check components Gear changeover is not working Leaf springs not sitting in guide sleeve Check components Clutch ring inserted incorrectly Check compone...

Page 67: ...ial tool for electrical troubleshooting You can use the test board for ASCS 4 8 6 3 ASCT 14 18 ASCM ABOP 6 10 13 2 Since the motor cannot be tested directly you can use the test board to check the functions of switches and torque potentiometers if present The test steps and nominal values for use with the test board are provided on the next page 8 Troubleshooting electrics Tool Test board 6 41 34 ...

Page 68: ...tery data Passage 10 Ω Battery data blue Pin 6 Right left Passage Position 1 1 MΩ Position 2 10 Ω Pin 4 Pin 5 Speed potentiometer total resistance Resistor 20 kΩ 4 kΩ Pin 4 Pin 2 Speed potentiometer resistance range Resistor 0 Ω to 20 kΩ 4 kΩ proportional to potentiometer travel Switch not pressed 0 Ω Switch pressed 20 kΩ 4 kΩ Pin 4 Pin 3 Tool dependent tests Torque potentiometer total resistance ...

Page 69: ...0 13 2 All rights reserved by FEIN especially in case of industrial rights registration FEIN retains all rights of disposal such as copying and circulation C SC_CSSM 2012 08 69 69 Version 1 9 Connection diagram ...