SERVICE INSTRUCTIONS FOR MODEL NO. 8800ES
WARNING
Disconnect power before doing any repairs!
SAFETY
Hypot Testing
Each 8800ES series tool that is serviced must be Hypot tested before being shipped back to the
customer. If you do not have this equipment, you can not service this tool.
Hypot testing is a safety test required by Underwriter’s Laboratories. It basically ensures that there are no live metal parts exposed on the product. This condition could occur if, for instance:
1.A housing screw went through a wire.
2.A wire was stripped back too far and the bare wire contacted a bearing or the driveshaft.
3.A wire was damaged and came into contact with a bearing or the driveshaft.
This is a very serious safety issue so please take care to test the tool as specified below.
The tool is to be Hypot tested at 3000 VAC for 1 second between:
A.Both power cord prongs and the chuck with the power switch in the ON position.
B.Between the power cord prongs and all of the housing screws with the power switch in the ON position.
The maximum allowable current is 0.5mA.
REPAIR
The following are specific instructions for repairing the 8800ES drill. For a list of available service parts and an
These repair instructions start with the very basic repairs such as replacing a chuck and progress to the more complicated such as replacing a housing. They are done this way so all of the information does not have to be repeated. For this reason you may want to read the entire instruction before proceeding with one of the more compli- cated repairs.
4.Place tool on its side and hold firmly.
5.Using a wooden mallet strike the longer end in the clockwise direction.
Installation
1.Screw the chuck on by hand as far as it will go.
2.Insert screw
3.Tighten the chuck around the shorter end of a 1/4” or larger hex key, then strike the longer end in the clockwise direction with a wooden mallet while holding down the tool securely.
4.Tighten the screw once again by turning in a counterclock- wise direction.
BRUSH REMOVAL / INSTALLATION
Removal
1.Remove brush cap using a
2.Remove brush assembly from the brush holder.
Installation
1.Installation is the reverse of the removal instruction above.
GEARBOX REMOVAL / INSTALLATION
Currently, the gearbox components are not individually available, and in the event of a failure, the entire gearbox must be replaced.
The procedure for removing / installing the gearbox is as follows:
Removal
1.Remove the chuck as described above.
2.Remove the brush caps and take out the brushes. The brushes should always be removed before disassembling the housing.
3.Remove the (8) housing screws and remove the right housing half. While removing the right housing half, disconnect the yellow brush lead from the brush holder. This can usually be disconnected with your fingers. If not, a
4.Remove the chuck shroud.
5.Lift up the gearbox so that the motor assembly tips upward. Once the gearbox is above the left housing half, pull it away from the motor so the input shaft pulls out of the motor coupling.
CHUCK REMOVAL / INSTALLATION
Removal
1.Open chuck jaws to maximum capacity.
2.Remove retaining screw on tool by turning it in a clockwise direction (screw has a
3.Insert the shorter end of a 1/4” or greater hex key into chuck and tighten.
Installation
1.Remove the armature while leaving the field in place. In order to remove the armature, you will have to tip up the field so that the fan clears the housing.
2.Ensure that there is grease in the motor coupling and that the
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