REPAIR INSTRUCTIONS for Model 8960-20 No. 8960-20 8 Gallon Dust Extractor MILWAUKEE TOOL www.milwaukeetool.com 13135 W. LISBON RD., BROOKFIELD, WI 53005 58-92-8960 042017 Drwg.
Index Construction A. Safety issues 4 B. Technical data 5 C. Construction / function 6 D. 10 Troubleshooting E. Service / repair 12 F. 27 Spare parts G.
Preface A In this manual you will find the essentials you need to know when repairing wet and dry cleaner 8960-20. A fault in the equipment can have a number of causes. Chapter D Troubleshooting will help you here. Technical information sheets are a supplement to the spare parts list until a follow-on publication. When carrying out repairs, make sure you have a suitable workbench or the like with the necessary power supply available. Use the illustrated spare parts lists for your repairs.
A Safety issues Observe national safety directives and regulations for the electrical engineering trade, in particular: For your own safety. IEC 60335-2-69 EN 60335-2-69 DIN VDE 105 part 1: operation of electrical power installations. Repairs should only be made by someone who has received proper instruc ons for the job or who is a qualifed electrician. WARNING: The upper sec on of the machine contains live components. Contact with live components leads to serious or even fatal injuries.
B Technical data Model 8960-20 Possible Voltage V 110-120 W HP 890/7,4A 1,2 Connected Load for Appliance Socket W 550/4,6A Mains Frequency Hz 50/60 Fuse A 15 Power P IEC Protection Grade (moist, dust) IPX4 Protection Class (electrical) I Maximum Airflow* l/s m³/h CFM 70 252 148 Maximum Vacuum kPa hPa in H2O 23 230 92 Sound Pressure Level L PA (IEC 60335-2-69) dB(A) 69 ± 2 Working Sound Level dB(A) 60 ± 2 Vibration ISO 5349 an m/s² <2,5 kg lb 14,5 31,9 m/s² 0,5 Weight
C Construction Hatchback Solenoid actuator Filter cleaning system Motor unit Full tank sensor Flow sensor PCBA Buzzer alarm Control panel Control panel Motor speed control Rotary on/off switch Socket for power tools 6
C Construction Main filter element, PTFE Floater - full tank sensor for liquids Container clamp Air flow cover AntiStatic grounding clip 30 ltr container 7
Function Airflow 8 C
Function C Automatic filter cleaning system Even with extremely fine dust the automatic filter cleaning function allows you to work constantly with the same suction performance without having to manually clean the filter. A powerful reversed air pulse is activated every 15 seconds keeping the air flow on a high level. The air pulse is created by a solenoid connected to a piston with double-valve.
D Troubleshooting Motor not working with switch set to ”I” Check: Yes - Mains voltage present? - Power cord plugged into socket? - Switch set to “I” ? No Connect motor directly to mains. Is motor working? No Replace motor. Check if machine is working correctly. Calibrate flow sen- Yes Connect motor directly to switch. Is motor running? Yes No Check connections and replace switch if needed. Yes Connect switch - PCB - motor. Is motor running? No Check connections and replace PCB if needed.
D Troubleshooting Motor not working with switch set to ”AUTO/TOOL” Check: Yes - Mains voltage present? - Power cord plugged into wall socket? - Switch set to “AUTO/TOOL” ? - Load with > 60W plugged into socket? Connect motor directly to mains. Is motor working? No Replace motor. No Check if machine is working correctly. Calibrate flow sensor if needed (section E.10). Yes Yes Disconnect socket. Job done!! Connect motor directly to switch.
E Service / repair 0. Disassembly 13 1. Change motor unit 18 2. Change power cord 19 3. Replace rotary switch 20 4. Replace power socket 21 5. Change hatch back clamp 22 6. Change H-class/HEPA filter 23 7. Change pressure switch 24 8. Change solenoid 25 9.
Disassembly E.0 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. TIP: Unless otherwise stated a TX20 bit is needed for the screws. Always disconnect the mains plug before disassembly. Dismount topcover and filter 1 2 Loosen and lift the top part of the handle with a flatheaded screwdriver and unscrew the lower part of the handle (fig.1). Unscrew the topcover (fig.2).
Disassembly E.0 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. Always disconnect the mains plug before disassembly. Open the hatch back and take out the filter (fig.3). 3 Disconnect and dismount Hatch back Unscrew the cable relief using a TX10 bit (fig.1).
Disassembly E.0 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. Always disconnect the mains plug before disassembly. Disconnect and dismount Hatch back (continued) 2 3 Disconnect the two solenoid wires from the grounding (fig.2) and the PCBA (fig.3).
Disassembly Disconnect and dismount Hatch back (continued) 4 Dismount the hatch back by pressing the hinge in each side (fig.4). 16 E.
Disassembly E.0 TIP: Before disconnecting wires check if a letter is placed in the plastic next to the connector. This letter will refer to a letter on the PCBA and in the electrical diagrammes.
Change motor unit E.1 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. 1 Always disconnect the mains plug before disassembly. Motor connection to PCBA Full tank sensor connection to PCBA Motor connection to swicth Disassemble the handle, top cover, filter and hatch back as described in previous Section E.0. Disconnect the full tank sensor wire and the motor wires from the PCBA and the switch (circles in fig.1).
Change power cord 1 E.2 3 2 Disassemble the handle, top cover, filter and hatch back as described in previous Section E.0. Disconnect the wires on power cord from their connection points on switch and earth grounding (fig.1-3). Unscrew the cable relief (use TX10 bit) and pull the cord out of the relief hole (fig.4). Install new power cord of same type as original. Then repeat the process backwards to assemble the machine. Be carefull to place the cord in the proper cable guides.
Replace rotary switch E.3 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. Always disconnect the mains plug before disassembly. 1 2 Disassemble the handle and top cover as described in previous Section E.0. Take off control panel and disconnect the wires on the switch (fig.1). Unscrew the rotary knob and dismount the rotary switch (fig.2). Then repeat the process backwards to assemble the machine.
Replace power socket E.4 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. Always disconnect the mains plug before disassembly. 1 2 Disassemble the handle and top cover as described in previous Section E.0. Take of control panel and disconnect the wires on the power socket (fig.1). Unscrew the power socket and replace it (fig.2).
Change hatchback clamp E.5 1 2 3 A B Disassemble the handle and top cover as described in previous Section E.0. 3 Unscrew the two plastic covers on the hatch back (fig.1). Dismount the clamp by pressing the outer metal pin ”A” from left side (fig.2). Notice position of the spring (fig.3). Dismount the clamp lever by pressing the outer metal pin ”B” from left side (fig.2). Replace the clamp. Repeat the process backwards to assemble the machine.
Change H-class/HEPA filter E.6 1 2 Open the container clamps (fig.1) and turn motor head upside down. Unscrew and remove the orange filter cover (fig.2). Take off H-class/HEPA filter and dispose it in a safe manner. WARNING: Filter might be contaminated by hazardous dust. Wear a P2 breathing mask and avoid spreading harmful dust. Install new filter gasket and make sure it is in correct position (fig.3). Install new H-class/HEPA filter (fig.4).
Change pressure switch E.7 WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. Always disconnect the mains plug before disassembly. 1 Disassemble the handle and top cover as described in previous Section E.0. If the pressure difference 20-30 mbar over the ’+’ connector the pressure is ok (fig.1). Disconnect the pressure switch wire from the PCBA (fig.2). Unscrew the pressure switch (fig.3) and replace it incl wiring.
E.8 Change solenoid WARNING: The upper section of the machine contains live components. Contact with live components leads to serious or even fatal injuries. 1 Always disconnect mains plug before disassembly. 2 3 B A Disassemble the handle and top cover as described in previous Section E.0. Unscrew the two plastic covers on the hatch back (fig.1). Disconnect the solenoid wires from PCBA and earth clip. Relieve the solenoid and unscrew the cable relief (fig.2).
Change castor wheels 1 Unscrew the defect wheel including the bushing connected to the container. Mount the parts in the order laid out in fig.1: bushing (which must flush with the container surface), washer, wheel, screw. To improve the stregth and fixation of the castor wheel it is recommended to use Loctite or similar between the bushing and the screw. 26 E.
F Spare parts 16 17 18 22 13 ø27 6 ø3 1 ø2 ø32 ø38 14 19 20 1 2 12 7 8 6 15 3 16 9 7 11 10 16 21 FIG. 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 DESCRIPTION OF PART Rotary Knob O-Ring 2.
F Spare parts 2 1 2 FIG. 1 2 3 4 5 6 7 3 5 DESCRIPTION OF PART Hatch Door Frame Assembly 5 x 18 Screw Solenoid Kit PT35 x 18 Screw Cord Clamp Hatch Door Filter Gasket Kit Main Filter NO. REQ. 1 15 1 2 1 1 1 4 7 6 3 10 1 13 2 4 14 11 12 5 6 7 8 28 FIG. 1 2 3 4 5 6 7 8 10 11 12 13 14 DESCRIPTION OF PART NO. REQ. Foam Pad 1 Hatch Door Hinge (Set of two) 1 Reed Sensor Assembly 1 Circuit Board Assembly 1 3.
F Spare parts 5 4 3 2 FIG. 1 2 3 4 5 6 1 DESCRIPTION OF PART Sound Filter 3.5 x 18 Screw Cord Clamp Distribution Strip Container Clamp Power Cord NO. REQ.
F Spare parts 6 7 2 8 302004203 302004201 302004200 5 WARNUNG: Dieses Gerät enthält gesundheitsgefährliche Stäube. Entleerung und Wartung einschließlich Entfernung des Staubbeutels dürfen nur von sachkundigen Personen vorgenommen werden, die geeignete persönliche Schutzausrüstung tragen. Nicht einschalten bevor das komplette Filtersystem installiert und die Funktion der Volumenstromkontrolle überprüft worden ist. 4 9 1 10 3 11 FIG.
F Spare parts 4 FIG. 2 3 4 5 7 11 13 14 15 16 17 18 19 DESCRIPTION OF PART NO. REQ. Hose 1 Quick System Hose Sleeve 1 Hose Sleeve 1 Curved Hand Tube 1 Power Tool Adapter 1 Floor Nozzle 1 Universal Nozzle 1 Brush Attachment 1 Wet/Dry Floor Nozzle 1 Industrial Floor Nozzle w/ Brush 1 Vacuum Hose Adapter (Not Shown) 1 DEK26 Adapter (Not Shown) 1 DE Adapter (Not Shown) 1 3 2 5 11 13 14 7 15 1 16 2 x5 5 FIG.
G Electrical diagrammes Reed switch PCBA Motor Socket Speed Main switch / Mode selector Solenoid For 120V US For 100-120V 32
Electrical diagrammes PCBA TYPE P2 33 G
Electrical diagrammes Wire overview 49 G
