R10086

DW158 DW165       Heavy Duty Drills

DW158 = 'P' handle Drill
DW165 = 'D' handle Drill.
Item numbers = ('P' handle, 'D' handle).

Recommended grease is 870889-49 (5 kg container).

The spindle (129, 140) should be smeared with a little grease on assembly to prevent galling under the bearing.
The hammer face (137, 147) should be smeared with grease on assembly.

Type 1 units only
To assemble gearbox speed change mechanism:
Turn the knob (148, 159) clockwise until the number 1 is adjacent to the arrow on the gearcase.
Turn the knob clockwise until 2 clicks are heard.
This is the selector fork (145, 156) moving over the teeth of the selector shaft (144, 155).
Turn the knob anti-clockwise so the 1 aligns with the arrow.

Fill the gearbox with 35 gms of grease.
Fit the shield (142, 153) and fill with 3 gms of grease.
Fit the layshaft (143, 154).

Tighten the chuck to 60 Nm.

Maintenance checks
Refer to standard maintenance routine.
Unit specific checks:
Replace carbon brushes (105).
Check safety clutch operates.

Type 1 units are fitted with a "Metabo" sourced gearbox
Type 2 units are fitted with an in-house "North Star" gearbox
Type 3 / 4 units using “North star” wire up and dipped fields

DW165 only
To accomodate the North Star gearbox a new armature was developed with a 2mm reduced diameter on the fan end of the armature.   Unfortunately this was not ready at the launch of Type 2  and a reworked Type 1 armature was used incorporating a reducing sleeve.
At the same time two different fan end bearings were used,  one with a 10mm inner diameter and one with a 8mm inner diameter depending on the build level of armature.
The current Type 2 armature (with bearing fitted) can be used on both Types 1 & 2.
A Service kit has been introduced for Item 117 fan end bearing.  This includes both types of fan end bearing used (with 8mm and 10mm inner diameters).