Bosch Power Tool Service Spare Parts & Technical Information BOSCHDISCLAIMER For use in all Parts Lists and Repair Instruction Books “All reasonable care has been taken by Robert Bosch Limited in the preparation of this manual but no warranty can be given in respect thereof and Robert Bosch Limited will not be liable to any person firm or company whatsever: — (1) For any loss damage or injury resulting either from the adoption of any of the methods of repair or the use of or defects in any of the equipment referred to in this manual. (2) Without prejudice to the foregoing for any loss damage or injury caused by the use of this manual including any supplements or revisions thereto’PREVENTATIVE MAINTENANCE AND SAFETY CHECKS Inspect machine for signs of grease leaks (any signs of leakage refer to repair instructions) Inspect machine casing for damage, cracks etc. (Replace as necessary). Check for missing or broken screws, replace as required. Inspect tool holder for wear or damage. Clean and lubricate. Check operation of switch, inspect cable and replace if worn or damaged. Electrical safety checks must be carried out, i.e. insulation flash test 4,000 volts. (B.S. 2769) Check data plate, all information must be clear and easy to read. Labels or plastic tape showing the correct voltage of the machine should be attached where possible, to the cable and body of the machine. Itis important when servicing the machine, to remove all the old grease from the impact and barrel mechanism replacing with new grease. Check quantity required, see lubrication chart for part number and specification. DO NOT OVER GREASE After approximately 100 hours use, it is recommended that a full routine service is carried out. USE ONLY GENUINE BOSCH REPLACEMENT PARTSModel 11206 Lubrication Model 11 206 Modifications reserved Lubrication Point Fig/pos | Lubricant/grease/oil | Quantity Lubricating instructions Ball bearing, needle bearing 43, 44, 45, 5700 005 025 Grease 46, 47, 48, (rive | 49. Screw in cover 40 | Half fill opening Sliding parts, bearing bushings | 21,2223, | 700062025 Lubricate giding surfaces and guide parts 24, 29, 34, iee1v27 35, 53, 54. Sealing ring 55 Fill cavity between sealing lips Seal ing 57 8700 002.025 ‘Apply grease (Fetva) Gear and percussion 5700 062 025 100Gr. | Fill | mechanism space LV teeiv27) Modifications reserved | Resistance (20°C) Admissible overtemperature at load Voltage | Current consumption (no-load running) Of rotor (Of one stator coll | Motor | Mechanism | Too! holder v A Ohms Ohms °c °C °c 110 44-51 1.025—1.175 0.525—0.597 118-125 42-49 135 —1'55 0.68 —0.78 ft ral mm 220 22-26 4.50 —5.10 2.62 —2.98 240 (250) 2.0-2.4 5.35 —6.05 3.56 — 4.04 Insulation test protection class It Minimum diameter of commutator: 26.5mm Cut off brushes are fitted to this machine,TECHNICAL DATA Service Tools Tools with a KDEW prefix are available from your local Bosch Distributor Kukko extractors are available from Kukko Agents only Technical data Modifications reserved Te 0.611 2060 Storke ra Frequency 1~50 He (c/s) Voltage 42v | 100-110v|115-125v| 220v| 240-250v Nominal current roa} saa [73a 3a | 354 Drilling range with full dels 6:35 mm (1 3/8") ‘with dell bis up to 6 80 mm (3.1/8") with self driling anchors 9:12 mm (1/2") with dil chuck 5-13 mm (3/16" 1/2") 2.900 / min 380 mm (18") 5,6 kg (12.3 Ibs) Model 11206Model 11206 Dismantling Instructions | 4. Teot holder and locking pin 14 Shatt sealing ring 2. Exploded view (too! holder). 3. Handle, switch, wiring, | 3.1. Second section of handie 4, Gear box housing 4.1 Bearing block, impact mechanism.Eccentric shaft, coupling, gear wheels. Model 11206 5.1 Circlip, needle cage. 6.2 Switch lever, eccentric shaft, 6. 6. Cetbon brushes. 7. Remove ring nut (screw-in cover! with pin wrench 7.3 7.1 Intermediate support, armature ~~ 7.2 Remove screw 87 Exploded view Bearing cap piece, fan brush holder, armature. 7.3. Press ball bearing out of bearing cap piece with pin.Model 11206 8. 84 8. Remove gasket rng. 8.1 Remove stator coil 8.2 Press out needle bearing with Kukko 21/2 internal extractor. 8.3 8.3 Press out bearing bush with pin. Kukko 2172 8.4 Press out bearing bush with pin, 8.4 8.5 85 Withdraw needle bearing with Kukko 21/5 internal extractor. Kukko 21/5 9. Clean parts (wash) examine and if necessary, replace by new ones. Flat plate214 21.2 ws Assembly Instruc’ Allpartsare cleaned and worn and damaged parts have | g| been replaced. a1 gl \ 3) 21. Motor housing item 1 Ww 5 Push in needle bearing 47 and bearing bush 41 . from gear box side, 21.1. Pay attention to measurement for bearing bush 41 21.2 Insert felt ring and dise and push in bearing to measurement. 21.5 21.3: Press sealing ring in flush with pin. + 8 214 Insert pressure spring and detent ball into hole and then insert eccentric shaft with O-ring, attach ‘switch lever (pay attention to assembly position) and screw tight ~ 21.5 Insert stator. | A ~ - 22.1) 22. Press bleating ona step f 3 22.1 Assemble armature completely according to Fig. | screw in screw 87 and tighten, | 22.2 Insert preassembled armature into motor housing and screw tight. 120Nm Model 1120622.3 or er) Model 11206 22.3 Insert ring nut (screw-in cover) and tighten with pir wrench. 23. Insert carbon brushes, assemble cover I *60-80Nm | 24. Insert pin cage and secure with circlip 24.1 Insert safety coupling, eccentric shaft and serrated shaft | Retain steel balls with grease to assist assembly. 242 Assemble impact drive and bearingblock according | 1oF ig. 24.3 Insert gear box housing and switch ring. Do not forget grease!25. Mount handle section. 25.1 Mount switch, cable, capacitor and handle section 26. Push double-looped shaft sealing ring into too! helder with bush, Pay attention to assembly position! Assemble driver and impact bolt. Model 11206 ‘Mount locking pin and screw on tool holder. Do not forget seall Circuit diagrams, Insulation flash test to BSI 2769 Test run Test hammer, carry out electrical and mechanical test, Carry out test drilling!Model 11206 1903 230013 7mm Ill DIN 5401-B Type 1618 598 124 16102500003 ge 1.614.630 001 ca | \ ( goo8 velo 1610 251 002 1610 499 009 1610 508 008 086 1610 190 007 4 | | . 087 1 1618598091 1 Splined shaft 11-202 (1 618 598.087) 11.203; 11.206 2 1618 5980921 Drill holder 3 1610400024 Protective sleeve 4 1614632000 1 Compression spring 5 1610210035 1 O-ring g 11x 7mm 6 1610210036 1 O-ring 15% 6mm. DT 7 1903230013 § Ball 7mm 111 DIN 5401-8 9 16105080041 Support ring 1618 598 086 901 1610508003 1 Support ring 1 618 598.087Model 11206Model 11206 Modifications reservedType 1 612 025 020 = G43mm 4 Ma 1611 316 003 t 2 43mm we 73 Os 1.613 521 001 5 7613 100012 —6 U T613 480 008 IN oMé 1612 025 020 Pers 040 032 1 hs SS 7611 030 009 L 1.613 300 006 MB 5 Sar 1612 025 019 | Modifications reserved Model 11206Model 11206 Accessorypot panto, Oy. Dessipton =o No. Paro, Gy. __Dasuipton _—=—=Pon No. PartNo. Gy. —__Devsipton T0061 2080, 26 1618687023 + Tool holder ony Gi 1614616008 1 Compression ping J 1615 102083 1 Motor housing 31 1616303001 1 Spur gear 51 teeth 65 1614619004 1 Compression spring 21614220087 1 Fak winding 40v ; pos. 2.00.04; 2.00.05 32 1616312000 1 Splined shaft 14/22 teeth 66 1614611002 1 Compression spring 201 1614 220 056 Field winding 110v co 1616110025 1 Eccentric shaft 36 teeth 7 1604 652006 2 Coil spring 2614010016 1 Armature? woth 240 | 240002 1613100011 1 Beating ural 1803200007 1 Bally 11 DIN SO-S without fan pos. 16 5 328011 1 lide bush 6 1903 230011 6 Ball 6mm 111 DIN 5401-B 301 1614010015 Armature 110v . pene cee eee 361817000679. + Ecoontc shat 70 2810021 122 1 Screw AMax1201N840.8 4 167 2pole 7 1610506015 1 Guiding sleeve n 2910022164 2 ScrewAMSx 25 DIN84-5.8 18A/250v 3B 1610300046 1 Bearing bush 72 2910021118 2 Screw AM 4x8 DIN 84.8.8 50002 1900452011 2 Wire sleeve A1-6 DIN 46228 | 39 1616 490008 1 Shiftring B 1613 454002 2 Screw 6 1600703010 1 aaa 40 1613344002 1 Thread ring 4 2910141168 4 Screw M5x 35 DIN 9128.8 ; soxsonare 1 es 20mm a 1610506013 1 Bearing bush 6 1613414006 4 Screw, ! iceman 42 1610506014 1 Bearing bush eee ee 8 1611104001 1 Type name plate blank a 1610913004 2 Needle cage 78 1603 435008 2 Screw B4,8x 63mm ae 2 seriou 2 nonesonsoscH |S onsen > hoes 2o|02H BY 4 SomszeexmON Er 7 og 117228002 1 Supression erator 28), ygypatso02 1 Needecoge ae eae 2 eee ete ea goose Siero aeers 46 1600810011 1 Needle stove 81 2910601 118 2 Screw 39x19 DIN7872 ; 2 2910211218 8 Surew® 39x 18DIN7O71 47 1610810058 + Needle seve 131616122017 1 Handle2pieces 2 ene a Terres | ee ee 832910021 16.2 Screw AM 4x6 DIN B48 uy 1615500205 2 Housing cover 629-2 Z DIN 625 4 1600 150006 2 Spring washer 18 1618608048 1 Bening cover je 1610920001 1 Wostebexing BEGET Sm on : 8 2916680012 1 Retaning ng ieee 5 1610101608 1 Supporting washor Retaining ting 1% Yo160p0 1 Susnnoltercamnre | sz__1610101877 1 Suppornowaner | pg__—agoL09106 1 Connsten tina 2 Bi ooo | Conoliever 531610102615 1 Supporting washer 87 1613454001 1 Screw M5 te 16t5¢oncze Gearbox 5 Y610102614 1 Supporingwosher gg 623810011. Rubber pate 33» 10x 8mm 2 618700041 1 Non - a et aes ea eret Lee) 95 1610 101609 1 Supporting washer aoe ee s# Tet0s0000¢ 1 Resting na % 1810102017 1 Sinpring water tiker au pL Si0 20s boc m2 B Gel ng) 7 1611015020 1 Packing plate 231619124029 + impact bot 601610280008. 1 Supporting 24 1616490007 1 Guide bush 62 1900210104 1 Oving 8x2 Accessory 2 1616 490005 1 Driver 63 1611015018 1 Sealing gasket 1612025020 1 Handle assy. Model 11206Model 11206 Pos.No. PartNo. ay. Description Pos.No. PartNo. Qty. Description SET OF PARTS 800 1617014108 1 Setof carbon brushes 2pieces 801 1616333010 1 Bevel gear 31 teeth 802 1616333011 1 Bevelgear8 teeth 807 1617000014 1 Locking pin set with the pieces 27,28,59,61