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SPECIAL TOOLS Page 1 Core Drilling Machines SERVICE MANUAL
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SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Sep 09, 2020

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Page 1: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

SPECIAL TOOLS

Page 1

Core Drilling Machines

SERVICE MANUAL

Page 2: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Torque WrenchRange: > 100 Nm (22 mm square drive type)For BCR164/6 & BCR300/12 safety clutch

Art. 6.512.098

Torque WrenchRange: 0-25 Nm. (19 mm square drive or socket head type)For BCR130/5BG & MG safety clutch

Art. 6.512.097

Necessary Tools for machine assemblyBEAST by BBTEC Core Drilling Machines

Soft Hammer (preferred plastic head)

Art. 6.512.096

Circlip Pliers for external retaining rings(10-25 mm)

Art. 6.512.099

Outside snap ring Circlip Pliers(15-60 mm, with special tips for snap-rings and spring-clips)

Art. 6.512.100

Circlip Pliers for internal retaining rings(straight, 19-60 mm)

Art. 6.512.101

Service Manual

3

654

21

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Page 3: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Blind Bearing Pullers / Split Collet Pullers(8-10.5 mm, 10.5-12.5 mm, 13-17 mm)

Art. 6.512.104

Bench Press Tool

Special Toolkit Case(see Service Manual Special Tools for use of each tool)

Bearing Puller Tool(0-40 mm)

Art. 6.512.102

Separator Tool(D max. > 50 mm)

Art. 6.512.103

8

Service Manual

7

11

9 10

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Page 4: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Slide and …Slide the special tool on the drill spindle

LockLock the special tool with the gearbox to a vice

STEP 2

Special tool 08-170-162-01 to secure gear box with drill spindle to a vice

Service Manual – Special Tool 08-170-162-01BCR130/5BG & MG, BCR164/6, BCR300/12

08-170-162-01

STEP 1

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Page 5: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Service Manual – Special Tool 06-220-833BCR130/5BG & MG

Special tool 06-220-833 to assemble seals in BCR130/5BG & MG gear box

To assemble seals, position number 7, in gear box BCR130/5BG & MG, position number 23, see supported exploded view

Assembly parts• Gear box BCR130/5BG & MG

Part # 6.000.063• 2x Seals

Part # 6.502.013

Grease Apply silicon based grease to both seals

Grease and positionApply silicon based grease on the inside of the gear box.Position the first seal horizontally in the gear box with the open side upward.

STEP 1 STEP 2

06-220-833

Page 5

Page 6: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

06-220-833

PressPress the seal using the special tool all the way down.

Second sealPosition the second seal horizontally in the gear box with the open side downward. Press the seal using the special tool down until the ring levels with the wider part of the gear box.

STEP 3

STEP 4

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Page 7: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Service Manual – Special Tool 06-220-836BCR130/5BG & MG

Special tool 06-220-836 to assemble seals in BCR130/5BG & MG gear box

To assemble seals, position number 16, to gear box BCR130/5BG & MG, position number 23, see supported exploded view

PositionPosition the seal with the open side downward on top of the special tool. Turn over and place the tool above the seal hole.

GreaseGrease the seal hole with silicon based grease

STEP 2STEP 1

Assembly parts• Gear box BCR130/5BG & MG, part # 6.000.063• 1x Seal, part # 6.502.014

06-220-836

Page 7

Page 8: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

PressPress the the seal gently in the hole

STEP 3

06-220-836

Page 8

Page 9: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Special tool 06-220-837 to assemble ball bearings in BCR130/5BG & MG gearbox

To assemble ball bearing, position number 24, to gear box BCR130/5BG & MG, position number 23, see supported exploded view

Assembly parts• Gear box BCR130/5BG & MG

part # 6.000.063• Ball bearing part# 6.504.012

Grease and positionGrease the ball bearing hole with silicon based grease and position the bearing horizontally in the hole

Position tool and assemblePosition the special tool on the ball bearing. Tap with caution the bearing gently in place with a rubber hammer.

STEP 2

Service Manual – Special Tool 06-220-837BCR130/5BG & MG

06-220-837

STEP 1

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Page 10: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Assembly parts1 Gear spindle, part # 6.130.008 2 2x Washer, part # 6.130.0093 Bearing bush, part # 6.130.011 4 Gear wheel #2, part # 6.130.010 5 Ring, part # 6.130.0126 Spring washer, part # 6.505.017 7 Nut, part # 6.503.004

Used oil, cleaner and glue• Shell Spirax AX 80W-90• Würth saBesto IndustrieClean, part # 0893 140-E or

Loctite 7235 Nettoyant/Reiniger, part # 35953• ThreeBond 1374 glue

Service Manual – Special Tool 12-170-100-1 / 09-120-002-01 BCR130/5BG & MG

Special tools 12-170-100-1 and 09-120-002-01 for BCR130/5BG & MG safety clutch

• For fastening and adjusting the nut with a torque wrench

• To assemble a BCR130/5BG & MG safety clutch

Lock and mountLock the special tool in a vice and mount the gear spindle (1)

OilBrush oil on the gear wheel

MountMount the first washer (2)

STEP 3

12-170-100-1 / 09-120-002-01

7

6

5

4

3

1 2

STEP 2STEP 1

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Page 11: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

OilBrush oil on the washer (2)

OilBrush oil on the washer (2)

OilBrush oil on the gear wheel (4)

MountMount the bearing bush (3)

MountMount the second washer (2)

MountMount ring (5)

CleanClean nut thread of gear spindle oil free

GlueGlue thread of nut (7) with Three-Bond 1374

MountMount the nut (7)

MountMount spring washer (6)

SecureSecure ring (5) in correct place

MountMount gear wheel #2 (4)

STEP 15

STEP 12STEP 11

STEP 6

12-170-100-1 / 09-120-002-01

STEP 4 STEP 5

STEP 7 STEP 8 STEP 9

STEP 10

STEP 13 STEP 14

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Page 12: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

FastenFasten the nut (7) with a torque wrench hand tight

Mount toolMount the special tool

FastenFasten the special tool with a torque wrench to 16/17 Nm

AdjustNow repeat Step 15, 16 and 17 by loosening or fastening the nut (7) until the safety clutch slips with the torque wrench set to 16/17 Nm

STEP 19

12-170-100-1 / 09-120-002-01

STEP 18STEP 17STEP 16

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Page 13: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Special tool 06-220-835 to assemble seals and ball bearings in BCR130/5BG & MG motor cover

To assemble seal, position number 35, and ball bearing position number 36, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view

Assembly parts• Motor cover BCR130/5BG & MG, part # 6.130.013• 1x Ball bearing, part # 6.504.021• 1x Seal, part # 6.502.021

GreaseGrease the seal hole with silicon based grease

Position toolPosition the special tool on top of the seal

Position sealPosition the seal horizontally in the seal hole with open side down-ward

STEP 3STEP 2

Service Manual – Special Tool 06-220-835BCR130/5BG & MG

06-220-835

STEP 1

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Page 14: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Grease and positionGrease the ball bearing hole with silicon based grease and position the bearing

Press 2Turn over the special tool and center position the tool on top of the seal. Press the seal a second time.

Position tool, pressPosition the special tool on top of the ball bearing. Press the bearing in place.

Press 1Press the seal in place

06-220-835

STEP 5

STEP 6

STEP 7

STEP 4

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Page 15: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Special tool 06-220-834 to assemble needle- bearings in BCR130/5BG & MG motor cover

To assemble needle-berarings, position number 21, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view

Assembly parts• Motor cover BCR130/5BG & MG

part # 6.130.013• 2x Needle-bearings

part # 6.504.011

Grease and positionGrease both bearing holes with silicon based grease. Position the needle-bearings horizontally in the holes with shown text down.

Press 1Press both needle-bearings in the holes

Position tool and press 2Position the special tool and press the needle-bearings one by one in place

STEP 3

Service Manual – Special Tool 06-220-834BCR130/5BG & MG

06-220-834

STEP 2

STEP 1

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Page 16: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

08-170-165-01

Special tool 01-100-114-1 for BCR164/6 safety clutch

For fastening a BCR164/6 assembled safety clutch with a torque wrench

LockLock the special tool in a vice

PositionPosition the BCR164/6 assembled safety clutch in the special tool

SecureTighten the nut with a torque wrench to 9 kN/90 Nm. Attention: left handed thread

STEP 3

Service Manual – Special Tool 01-100-114-1BCR164/6

CCW

STEP 1

STEP 2

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Page 17: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Service Manual – Special Tool 08-170-165-01BCR164/6

08-170-165-01

Special tool 08-170-165-01 to support the fan when assembling to BCR164/6 armature

To support the fan, position number 38, when assembling to the BCR164/6 armature, position number 37, see supported exploded views

Assembly parts• Armature , part # 6.513.098• Fan, part # 6.513.099

Position Position the fan on top of the special tool with the metal ridge downward

Grease Lightly grease the the fan connect-ing part of the armature

Mount Mount the armature on top of the fan. You are now ready to press.

Press Press the armature on the fan in a straight upright position step by step while rotating the tool

STEP 4

STEP 3

STEP 2STEP 1

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Page 18: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Service Manual – Special Tool 98-0090-02HBCR164/6 / BCR300/12

98-0090-02H

Special tool 98-0090-02H to mount seals in the BCR164/6 or BCR300/12 water bush

To assemble 2x seals in water bush, BCR164/6: seals position number 55 water bush, position number 54 BCR300/12: seals position number 19 water bush, position number 18See supported exploded viewsAssembly parts

• 2x Seals, part # 6.502.1251. Water bush BCR164/6, part # 6.164.0402. Water bush BCR300/12, part # 6.250.020

Grease Apply silicon based grease inside the water bush

Put on seal 1Put the first seal on the long end of the special tool with the open side upward

Position tool Positon the tool over the water bush. Keep the ridge on the water bush to the bottom.

STEP 1 STEP 2 STEP 3

1 2

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Page 19: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

98-0090-02H

Press Press the seal in the water bush all the way down

Attention!Mount the lock ring, position number 56 on the supported exploded view

Position and press Positon the tool over the water bush. Press the second seal in the water bush.

Put on seal 2Put the second seal on the short end of the special tool with the open side downward

STEP 6STEP 5STEP 4

Page 19

Page 20: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

STEP 3

Special tool 98-0090-02G for BCR300/12 safety clutch

For fastening a BCR300/12 assembled safety clutch with a torque wrench

Service Manual – Special Tool 98-0090-02GBCR300/12

LockLock the special tool in a vice

PositionPosition the BCR300/12 assembled safety clutch in the special tool

SecureTighten the nut with a torque wrench to 9 kN/90 Nm. Attention: right handed thread

01-100-114-1

CW

STEP 1

STEP 2

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Page 21: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

98-0090-02G

GreaseGrease both bearing holes with silicon based grease

Slide and lockSlide the special tool on the drill spindle and lock the tool to a vice

Position toolPosition the special tool on top of the bearing

Assemble Tap with caution the bearing gently in place with a rubber hammer.

Position bearing 1Position a ball bearing horizontally in place

Assembly parts• Gear box BCR300/12

part # 6.000.060• 2x Ball bearings

part # 6.504.060

Special tool 08-170-161-01 to assemble ball bearings in BCR300/12 gearbox with drill spindle

To assemble ball bearings, position number 32, to gear box BCR300/12, position number 7, see supported exploded view

Special tool 08-170-162-01 to secure gear box with drill spindle to a vice

Service Manual – Special Tool 08-170-161-01 / 08-170-162-01 BCR300/121

STEP 4STEP 3STEP 3

STEP 1 STEP 2

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Page 22: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Position toolPosition the special tool on top of the second bearing

Assemble Tap with caution the second bearing gently in place with the rubber hammer.

Position bearing 2Position the second ball bearing horizontally in place

STEP 7STEP 5

08-170-161-01 / 08-170-162-01

STEP 6

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Page 23: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

08-170-161-01 / 08-170-162-01

Position lock ring

Mount lock nut

• Gear box BCR300/12 part # 6.000.060• Lock ring part # 6.505.090• Lock nut part # 6.503.070

Special tool 08-170-162-01 to secure gear box with drill spindle to a vice

Special tool 98-0090-02F to secure the drill spindle to BCR300/12 gearbox

To secure lock ring, position number 5, and lock nut, position number 4, for gear spindle to gear box BCR300/12, position number 7, see supported exploded view

Assembly parts

Service Manual – Special Tool 08-170-162-01 / 98-0090-02F BCR300/12

Slide and lockSlide the special tool on the drill spindle and lock the tool to a vice. ATTENTION: Be sure the ball bear-ings position number 32, part # 6.504.060 are first mounted according sheet 1 .

STEP 1 STEP 2

STEP 3

2

Page 23

Page 24: SPECIAL TOOLS Core Drilling Machines - Lackmondlackmond.com/media/wysiwyg/BEAST_BBTEC_Special_Tool_Service_Manual.pdfBEAST by BBTEC Core Drilling Machines Soft Hammer (preferred plastic

Position toolPosition the special tool over the drill spindle on the lock nut in such way that the tool tabs fits into the nut slots

Tighten nutSecure the lock nut hand tight

Position nutWhen tightened, position the lock nut in such way that one of the nut slots is above a lip of the lock ring

Bend lipBend the lip of the lock ring with a screwdriver into a positioned nut slot

STEP 4

STEP 5

STEP 6 STEP 7

08-170-162-01 / 98-0090-02F

Page 24