HOUSING REPLACEMENT
Removal
1.Remove the chuck as described above.
2.Remove the top housing half and gearbox as de- scribed above.
3.Remove the armature from the tool.
4.Remove the field as described above
5.Remove the switch as described above.
6.Remove the power cord from the tool. It should just pull out of the wire channel.
7.Disconnect the red brush lead from the brush holder in the left housing half and remove the switch wiring harness. Like the power cord, this should pull right out.
8.Press the brush holders out of each housing half.
Installation
1.Install a service warning label on the new housing. The service warning label is only partially laminated. Half of the label has a backing on the lamination that can be peeled off allowing the technician to write on the label and finish laminating it him/herself. Record the tool serial number with a pen on the label, peel the backing off of the lamination, and laminate the service warning label.
2.Install new decorative and brand labels if desired.
3.The remainder of assembly is the reverse of the removal instruction above.
WIRE ROUTING / REPLACEMENT
As noted in the above sections, it is very important to note the routing of the wires before disassembly. They must be routed exactly the same way upon assembly. Some additional detail on proper wiring follows.
It is very easy to pinch a wire when reassembling a tool if care is not given to wire routing. Take note of which ribs contact the switch and field, and where wires must be routed to clear them. The bundle of 4 switch wires must be placed with 2 of the wires in each of the 2 wire slots provided as the wires pass under the motor coupling.
Switch Wire Routing
One of the wires from the power cord must be placed in on top of each bundle of switch wires and pressed firmly into place. This will hold the wires down and away from the motor coupling.
Power Cord Routing
As an aid to reassembly, take note of wire routing and position in wire guides and traps while dis- mantling tool.
White wire #5 is to be routed around the lower brush boss between the boss and the field.
Yellow wire #7 must pass under the power cord wire and exit between the cord strain relief and the screw boss. This allows enough slack to attach the wire to the upper brush holder while lowering the housing.
WhiteYellow
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