R10085

DW490 DW491 DW492

Large Angle Grinders

To access the brushes remove the screws (46) and covers (42).

When removing the handle halves there are two screws under the left hand brush cover.

To remove the switch from the fieldcase, gently lever open the two arms on the front of the switch.

When refitting the handle check the dampers (43) are in position.
A little light oil or grease on the dampers will assist in fitting the handle halves.
When removing the gearcase the armature may be pulled out of the fieldcase. To avoid this use a thin screwdriver through the ventilation slots in the gearcase to hold the flange (31) against the fieldcase.

When refitting the motor, the rear bearing sleeve (34) must be fitted to the rear bearing before fitting into the fieldcase. If the sleeve is left in the fieldcase it may become displaced and allow the bearing to move when the tool is in use.

These units have grease lubricated gearboxes.
On reassembly fill the gearcase with 45-50 gms of grease.

Maintenance checks
Refer to standard maintenance routine.
Unit specific checks:
Replace carbon brushes (4, 51 where fitted).
Check condition of flanges (6, 9) and replace if worn.

QUALITY.
Bremas Switches
All large angle grinders received for repair should have the switches checked to ascertain which make of switch has been fitted to the machine. 
There are two manufacturers of the switch, Marquardt, Germany, and Bremas, Italy.
If the machine has a Marquardt switch fitted (identified by makers name on the switch body) these are OK and the machine should be repaired as normal.
If the machine has a Bremas switch fitted (identified by makers name on the side of the switch body) they MUST be checked as follows :

If the switch has a white dot on the switch body near to the date code, these are OK.
If the switch has a date code of 12-96 or greater, these are OK.
If the switch does not have a white dot near the date code, and the date code is less than 12-96, these switches must be replaced with a new switch from your stock.