Fein kbb38x, Repair Instructions

Page 1: ...epair instructions C SC_CSSM Version 1 0 2015 08 25 All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 1 of 56 ...

Page 2: ...e of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 2 of 56 1 Models described 2 Technical data 3 Notes and requirements 4 Tools required 5 Lubricants and auxiliary substances required 6 Removal 7 Fitting 8 Troubleshooting 9 Connection diagram ...

Page 3: ...l rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 3 of 56 These repair instructions describe how to repair the following models Model Order number KBB 38 X 7 272 12 ...

Page 4: ...al data All the 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: ... training Only use original FEIN spare parts Provisions Please note that power tools may only be repaired maintained and 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 The relevant accident prevention regulations of the employer s liability insurance associations are to be obse...

Page 6: ...tools Arbor press Chuck cone 22 mm 6 41 07 022 00 1 Cross tip screwdriver PH2 Chuck cone 28 mm 6 41 07 028 00 2 Socket head wrenches 2 5 mm 3 mm 4 mm 5 mm Drawing off socket cap 6 41 04 150 00 8 Open ended spanner WAF 10 14 Circlip pliers Slotted screwdriver Flat nose pliers Plastic hammer Sleeve 38 mm inner diameter 25 mm outer diameter 15 mm inner diameter 40 mm outer diameter 18 mm inner diamet...

Page 7: ...All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 7 of 56 Standard tools Press in bolt 10 mm diameter 25 mm diameter 28 mm diameter Ball bearing support 22 mm ...

Page 8: ...required C SC_CSSM Version 1 0 2015 08 25 All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 8 of 56 Lubricants Grease 0 40 127 0100 0 80 g Housing ...

Page 9: ...tions FEIN retains all rights of disposal such as copying and circulation Page 9 of 56 Removing the swarf guard and coolant tank 1 Open the protective grille 1 2 Loosen the set screw 2 3 Remove the protective grille 4 Unscrew the two screws 3 5 Remove the guide 4 Tools Socket head wrench 2 5 mm PH2 cross tip screwdriver 3 1 2 ...

Page 10: ...reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 10 of 56 Removing the swarf guard and coolant tank 1 Remove the hose 1 Empty the tank and pipe first 2 Remove the tank 2 1 2 ...

Page 11: ...posal such as copying and circulation Page 11 of 56 Removing the electronics 1 Unscrew the six screws 1 and remove the plate 2 Unscrew the screw 2 3 Pull off the two plugs 3 4 Pull off the two plugs 4 5 Pull the electronics 5 out of the cover 6 Unscrew the two screws 6 7 Remove the cover 7 Tools PH2 cross tip screwdriver Socket head wrench 2 5 mm 1 2 4 3 5 6 7 ...

Page 12: ...e of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 12 of 56 Removing the electronics 1 Pull the cables 1 off the switch 2 Unscrew the pushbutton 2 3 Unscrew the pushbutton 3 4 Remove the switch module 4 Tools Open ended spanner WAF 14 1 4 2 3 ...

Page 13: ...erved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 13 of 56 Removing the switch 1 Press the lock 1 on both sides with the screwdriver 2 Remove the switch Tools Slotted screwdriver 1 ...

Page 14: ...ions FEIN retains all rights of disposal such as copying and circulation Page 14 of 56 Removing the shaft 1 Unscrew the holder 1 2 Unscrew the two screws 2 3 Remove the intermediate gearbox 3 4 Unscrew the two screws 4 5 Remove the shaft 5 Tools Socket head wrench 5 mm Socket head wrench 4 mm Socket head wrench 3 mm 1 2 3 4 5 ...

Page 15: ...e of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 15 of 56 Removing the guide 1 Unscrew the screw 1 2 Use the spider to turn the drill motor 2 upward 3 Unscrew the guide 4 4 Remove the connecting cable 3 Tools Socket head wrench 5 mm 1 2 4 3 ...

Page 16: ...d by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 16 of 56 Removing the shaft 1 Remove the circlip 1 from the shaft 2 Remove the shaft 2 Tools Open ended spanner WAF 10 Circlip pliers 1 2 ...

Page 17: ...y FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 17 of 56 Removing the magnetic foot 1 Unscrew the four screws 1 2 Remove the magnetic foot and the tension belt Tools Socket head wrench 4 mm 1 ...

Page 18: ...ations FEIN retains all rights of disposal such as copying and circulation Page 18 of 56 Removing the guide plate 1 Unscrew the four screws 1 2 Remove the guide 2 3 Remove the terminals 3 4 Unscrew the earthing conductor 4 from the guide Tools Socket head wrench 4 mm Socket head wrench 3 mm PH2 cross tip screwdriver 2 4 3 1 ...

Page 19: ...by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 19 of 56 Removing the guide plate 1 Remove the cable 1 2 Unscrew the two screws 2 3 Remove the gear rack 3 Tools Socket head wrench 4 mm 1 2 3 ...

Page 20: ...erty rights applications FEIN retains all rights of disposal such as copying and circulation Page 20 of 56 Removing the motor housing 1 Remove the covers for the carbon brushes 1 on both sides 2 Take out the carbon brushes 2 3 Unscrew the four screws 3 Tools Slotted screwdriver Socket head wrench 5 mm 1 2 3 ...

Page 21: ...by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 21 of 56 Removing the motor housing 1 Lift the motor housing 1 off the gearbox housing using two screwdrivers Tools 2x slotted screwdrivers 1 ...

Page 22: ...case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 22 of 56 Removing the armature 1 Pull the armature 1 out of the gearbox housing 2 Pull the bearing 2 off the armature Tools Drawing off socket cap Chuck cone 22 mm Chuck cone 28 mm 2 1 2 ...

Page 23: ...culation Page 23 of 56 Removing the gearbox housing 1 Lift the intermediate gearbox 1 off the gearbox housing using two screwdrivers 2 Remove the seal 2 Replace the seal after each removal 3 Clean the gearbox housing 3 of grease 4 Pull off the grooved ball bearing 4 5 Tap out the gearbox shafts 5 Tools 2x slotted screwdrivers Chuck cone 22 mm Drawing off socket cap Plastic hammer 1 3 5 2 4 ...

Page 24: ... property rights applications FEIN retains all rights of disposal such as copying and circulation Page 24 of 56 Removing the gearbox housing 1 Remove the circlip 1 2 Remove the circlip 2 3 Press the shaft with bearing 3 out of gearbox housing Tools Circlip pliers Sleeve with 38 mm inner diameter 1 2 3 ...

Page 25: ...applications FEIN retains all rights of disposal such as copying and circulation Page 25 of 56 Removing the motor housing 1 Press out the sealing ring 1 2 Unscrew the screws 2 3 Slide the cables 3 through the motor housing 4 Take out the sleeve 4 Tools Sleeve with 25 mm outer diameter PH2 cross tip screwdriver 2 3 1 4 ...

Page 26: ...s of disposal such as copying and circulation Page 26 of 56 Removing the motor housing 1 Unscrew two screws 1 2 Remove the protective grille 2 3 Pull the respective cable 3 off the carbon brush holders 4 Drive out the field coil 4 5 Unscrew the two screws 5 6 Take the field coil out of the sleeve Tools PH2 cross tip screwdriver Plastic hammer 2 1 3 4 5 ...

Page 27: ...property rights applications FEIN retains all rights of disposal such as copying and circulation Page 27 of 56 Removing the shaft 1 Unscrew the hose socket 2 and remove the holder 1 2 Remove the circlips 3 3 Remove the discs 4 4 Remove the rings 5 Tools Open ended spanner WAF 10 Circlip pliers 5 4 3 2 1 ...

Page 28: ...n case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 28 of 56 Removing the shaft 1 Remove the circlip 1 2 Remove the disc 2 3 Remove the sealing ring 3 4 Remove the pressure piece 4 5 Remove the spring 5 Tools Circlip pliers 3 5 2 4 1 ...

Page 29: ... in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 29 of 56 Removing the spider 1 Unscrew the three handles 1 2 Use flat nose pliers to hold the nut 2 in position 3 Unscrew the screw connection 3 Tools Flat nose pliers 2 1 2 3 3 ...

Page 30: ...ty rights applications FEIN retains all rights of disposal such as copying and circulation Page 30 of 56 Fitting the shaft 1 Insert the pressure piece 1 into the spring 2 2 Insert the spring 2 into the shaft 3 Insert the sealing ring 3 4 Insert the disc 4 5 Insert the circlip 5 Tools Circlip pliers 2 1 3 4 5 ...

Page 31: ...lation Page 31 of 56 Fitting the shaft 1 Insert the circlip 1 into the groove of the shaft 2 Insert the disc 2 3 Insert the rings 3 into the distributor 4 Slide the distributor 4 onto the shaft 5 Insert the disc 5 6 Insert the circlip 6 into the groove of the shaft 7 Screw the hose socket 7 with the holder 8 onto the distributor Tools Open ended spanner WAF 10 Circlip pliers 1 2 5 6 7 3 4 8 ...

Page 32: ... retains all rights of disposal such as copying and circulation Page 32 of 56 Fitting the motor housing 1 Slide the stator 1 into the sleeve 2 Screw down the stator in the sleeve 2 3 Slide the sleeve with stator into the motor housing 3 Observe the correct position of the recess 4 for the cables Tools PH2 cross tip screwdriver 1 3 2 4 ...

Page 33: ...pecially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 33 of 56 Fitting the motor housing 1 Screw down the sleeve in the motor housing 1 2 Install the sleeve 2 for the stator cables Tools PH2 cross tip screwdriver 1 2 ...

Page 34: ...as copying and circulation Page 34 of 56 Fitting the motor housing 1 Feed the stator cables 1 through the sleeve 2 Connect the stator cables 2 to the brush holders PLEASE NOTE Bend the connections towards the motor housing after connecting them otherwise there is a risk of the connecting cable grazing the armature later on Tools Flat nose pliers Slotted screwdriver 2 2 1 ...

Page 35: ...retains all rights of disposal such as copying and circulation Page 35 of 56 Fitting the motor housing 1 Remove the bearings 1 2 Insert the disc 2 into the bearing seat of the armature 3 Press the armature 3 into the bearing seat Tools Arbor press Sleeve 25 mm outer diameter 15 mm inner diameter Ball bearing support 22 mm diameter 3 2 1 ...

Page 36: ...copying and circulation Page 36 of 56 Fitting the gearbox housing 1 Press the sealing ring 1 into gearbox housing in the correct position The smooth side of the ring facing outward 2 Press in the shaft 2 with grooved ball bearing 3 Insert the circlip 3 Tools Arbor press Press in mandrel with 28 mm diameter Sleeve 35 mm outer diameter 28 mm inner diameter Circlip pliers 1 2 3 ...

Page 37: ...in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 37 of 56 Fitting the gearbox housing 1 Insert the feather key 1 2 Press on the gear wheel 2 Tools Flat nose pliers Arbor press Sleeve 40 mm outer diameter 18 mm inner diameter 2 1 ...

Page 38: ... property rights applications FEIN retains all rights of disposal such as copying and circulation Page 38 of 56 Fitting the gearbox housing 1 Insert the circlip 1 2 Insert the gearbox shafts 2 together 3 Press on the bearing 3 Tools Circlip pliers Press in mandrel with 10 mm diameter Arbor press 3 1 2 ...

Page 39: ...applications FEIN retains all rights of disposal such as copying and circulation Page 39 of 56 Fitting the gearbox housing 1 Fill the gearbox 1 with 80 g of grease 2 Fit the seal 2 and seal the gearbox with the intermediate gearbox 3 Screw the gearbox to the drive unit 3 Tools Socket head wrench 5 mm 80 g grease 3 2 1 ...

Page 40: ...ons FEIN retains all rights of disposal such as copying and circulation Page 40 of 56 Fitting the gearbox housing 1 Insert the carbon brushes 1 on both sides and screw them down with the cover 2 2 Position the protective grille 3 and secure it with the two screws 4 Tools Socket head wrench 5 mm PH2 cross tip screwdriver 3 1 2 4 ...

Page 41: ...disposal such as copying and circulation Page 41 of 56 Fitting the shaft 1 Position the belt 1 in the recess on the magnet 2 Position the magnetic foot 2 with the belt on the housing 3 Screw in the four screws 3 4 Install the shaft 2 with feather key 3 gear wheel 4 bushes 5 discs 6 and circlips 7 Tools Socket head wrench 4 mm Circlip pliers 7 3 6 5 4 2 3 1 2 ...

Page 42: ...l rights of disposal such as copying and circulation Page 42 of 56 Fitting the guide 1 Insert the gear rack 1 2 Secure the gear rack with the two screws 2 3 Slide the connecting cable through the opening of the guide plate 3 4 Connect the stranded wires to the plug 4 The assignment of the pins is not relevant Tools Socket head wrench 4 mm 1 2 3 4 ...

Page 43: ... reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 43 of 56 Fitting the guide 1 Insert the two pins 1 into the gearbox housing 2 Put the flange 2 on the gearbox housing 1 2 ...

Page 44: ...rights applications FEIN retains all rights of disposal such as copying and circulation Page 44 of 56 Fitting the guide 1 Screw the earthing conductor 1 to the guide 2 Connect the motor and the connecting cable to the two terminals 2 The assignment of the pins is not relevant Tools PH2 cross tip screwdriver 1 2 ...

Page 45: ...ide 1 Position the guide 1 on the drill motor 2 Secure the guide with the two screws M6x30 2 and the two screws M6x35 3 PLEASE NOTE Raising and lowering the drill motor poses a risk of crushing at the cable Connecting cable must be laid in the guide rail intended for it 3 Put the drill motor 4 on the housing 4 Position the guide 5 5 Install the guide with the four screws with discs 6 Tools Socket ...

Page 46: ...5 08 25 All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 46 of 56 Fitting the guide 1 Slide the connecting cable 1 through the housing insert 1 ...

Page 47: ... of disposal such as copying and circulation Page 47 of 56 Fitting the spider 1 Slide the nut 2 into the connecting piece 3 and hold it in position with the flat nose pliers 2 Turn the screw connection 1 into the connecting piece 3 and all the way through the nut 2 3 Screw the three handles 4 into the connecting piece 3 Tools Flat nose pliers 2 1 2 1 4 3 ...

Page 48: ...top screw 1 2 Move the drill motor up and down with the spider 2 The drill motor must not jam or move down of its own accord If the drill motor jams or moves down of its own accord continue with step two 3 Loosen the screws 3 of the guide plate 4 Install the screws 3 of the guide plate 5 Move the drill motor up and down with the spider 2 Repeat steps two to four until the drill motor moves up and ...

Page 49: ... applications FEIN retains all rights of disposal such as copying and circulation Page 49 of 56 Fitting the electronics 1 Fit the switch 1 in the cover 2 Fit the switch module 2 Observe the correct position of the groove 3 Secure the switch module 3 4 Screw on the pushbutton 4 Tools Open ended spanner WAF 14 5 4 2 1 3 ...

Page 50: ...ts reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 50 of 56 Fitting the electronics 1 Screw the protective cap 1 onto the switch module Tools Open ended spanner WAF 14 1 ...

Page 51: ...pplications FEIN retains all rights of disposal such as copying and circulation Page 51 of 56 Fitting the electronics 1 Insert the cover 1 and screw it down with the two screws 2 2 Insert the electronics 3 into the cover 3 Connect the two cables 4 as shown in the connection diagram Tools Socket head wrench 3 mm 1 3 2 4 ...

Page 52: ...s of disposal such as copying and circulation Page 52 of 56 Fitting the electronics 1 Move the drill motor into the upper position 2 Screw down the earthing conductor 1 on the housing 3 Connect the plug 2 4 Connect the plug 3 5 Attach the cover 4 and screw it down with the six screws 5 Tools Socket head wrench 2 5 mm PH2 cross tip screwdriver 4 3 1 5 2 ...

Page 53: ...circulation Page 53 of 56 Fitting the shaft 1 Position the cover 1 and screw it down with the three screws with disc 2 2 Position the shaft and tighten the two screws 3 3 Position the holder 4 and screw it down with the two screws with disc 5 4 Screw down the holder with the two screws with disc 6 Tools Socket head wrench 4 mm Socket head wrench 5 mm Socket head wrench 3 mm 3 5 6 2 1 4 ...

Page 54: ... applications FEIN retains all rights of disposal such as copying and circulation Page 54 of 56 Fitting the coolant tank and swarf guard 1 Lay the hose 1 2 Secure the guide with the two screws 2 3 Attach the protective grille 3 4 Install the set screw 4 Tools PH2 cross tip screwdriver Socket head wrench 2 5 mm 1 4 2 3 ...

Page 55: ...8 Troubleshooting C SC_CSSM Version 1 0 2015 08 25 All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 55 of 56 ...

Page 56: ...on diagram C SC_CSSM Version 1 0 2015 08 25 All rights reserved by FEIN especially in case of property rights applications FEIN retains all rights of disposal such as copying and circulation Page 56 of 56 7 272 12 KBB 38X ...