Atlas Copco PBE 6 S Setup guide

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Repair Instructions No.182.03/98
PBE 6 S
Special Tools
Required
■ Torx screwdriver TX 30 4932 319 998
■ Forcing disks 4931 599 018
■ Pulling-off device 9170 314 440
■ Adjustment tool for carbon brushes 9170 302 270
Important! ■ Before beginning the maintenance work, perform an initial check with a high voltage test according
to VDE (see chapter Electrical and Mechanical Test Instructions).
■ Before all repair work, pull the power plug from the socket!
■ Vor der Demontage ist das Gerät an den RTR-READER (Wartungsmeßgerät) anzuschließen, um einen
evtl. Wartungsintervall abzufragen.
Disassembly
Removing the
auxiliary handle
1
Unscrew the nut (2) and remove the
washer (3).
2
Pull out the screw (6).
3
☞
Press the clamping ring (1) and re-
move the auxiliary handle (4). Release
the tension and remove the clamping
ring (1).
4
Push back the rubber sleeve (A) and lever
off the rubber bushing (5).
5
Remove the rubber sleeve (A).
6 Remove the locking ring (9) with aid of cut
special pliers. If necessary, use a screw-
driver for support.
7
Remove the damping element (8) and the
damper (7).
Disassembling
the ball holding
device
1 Remove all four balls (1) with aid of a
magnet.
2
Loosen the five screws (B) of the adapter
sleeve (2) and remove the adapter
sleeve (2) as well as the O-ring (3). If nec-
essary, hit it lightly with a plastic hammer.
3
Remove the tool acceptance (4) com-
pletely with the snap die (A), the
spacer (5) and the gasket (6).
4
Remove the snap die (A) from the tool ac-
ceptance (4).
5
Remove the O-ring (9), the spacer (8), as
well as the recoil ring (7).
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Repair Instructions No.182.03/98
PBE 6 S
Detaching the
carbon brushes
1
Loosen the screws (1) and remove the
brush covers (2).
2
Lift the brush springs (5) off the respective
carbon brushes (3) and place them on the
upper edge of the brush holders (4).
3
Pullbothcablelugs(handi)offthecarbon
brushes (3) and remove them.
Dismantling the
handgrip
1
Loosen the two screws (G) of the hous-
ing (F).
2 Remove the handle screw (E) by steady-
ing the knurled nut (5) at the same time.
Remove the knurled nut (5).
3
Loosen the screw (B) and lever off the
handle cover (A) from below (it is not pos-
sible to lever off the handle cover from
above without destroying it!).
4 Unscrew the four screws (6) from the right
half of the handle (7).
5
Unscrew both Torx screws (8) TX 30 of
the handgrip holder (4) and remove them.
6
Pull off the handle shells completely with
the housing (F).
7
Remove the damping element (2).
☞
Attention: Do under no circumstances
further dismantle the damping ele-
ment!
8
Disconnect the plug-in connection (1) be-
tween the motor and the pair of handle
shells.
9
Remove the handgrip holder (4) and the
rubber collar (3) from the handle shells.
10 Remove the left handle shell (C) with the
holding-down device.
11
Loosen the cable clamps (D) and lay bare
the connecting cable (H) with the cable
entry sleeve.
12
Remove the switch (9) with the capacitor
from the handle shell.
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Repair Instructions No.182.03/98
PBE 6 S
Detaching the
armature
1
Loosen the two short (A) and the two
long (D) screws.
2
Remove the motor housing (9) with the
field (1) and the air deflector ring (2).
3
Remove the air deflector ring (2) from the
motor housing (9) and expel the field (1)
from the motor housing (9).
4
Loosenthe screws (B).Remove the brush
holders (C) from the motor housing (9).
5
Pull out the complete armature by turning
it. If necessary, hit the motor housing light-
ly with a plastic hammer for support.
6
Remove the bearing sleeve (3) from the
armature bearing (4).
7 Press off the armature bearings (4)
and (8) with aid of the forcing disks
(service tool).
8 Remove the insulating disk (5) and the
ring (7).
Dismantling the
spindle
1
Peeloffthe ring(4)and remove theplastic
housing (5).
2
Remove the four balls (3) with aid of a
magnet.
3
Loosen the five screws (1) of the adapter
sleeve (2) and remove the adapter
sleeve (2). If necessary, use a plastic
hammer for support.
4
Remove the tool reception (8) completely
with the snap die (D), the spacer (7) and
the O-ring (6). Knock out the spacer (7)
through the grooves (E) with aid of a man-
drel.
5 Remove the snap die (D) from the tool re-
ception (8).
6
Remove the following parts:
grease seal (C),
spacer (B),
recoil ring (A) and
rubber ring (9).
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Repair Instructions No.182.03/98
PBE 6 S
Detaching the
flange
1
Remove the sleeve (2), and the O-rings
(3) and 4).
2
Loosen the screws (1) and remove the
flange (5) with the ring (8).
3
Remove the spindle sleeve (7) from the
housing (6).
Detaching the
gear box cover
1 Lever off the O-ring (1) and the grease
seal (2) from the gear box cover (3).
2
Unscrew the screws (8) and loosen the
gear box cover (3) by hitting the gear box
lightly with a plastic hammer. Remove the
cover.
3
Remove the gasket (6) and the insert (5).
4 Pull out the needle bearings (4 and 7) with
aid of an interior extractor.
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Repair Instructions No.182.03/98
PBE 6 S
Detaching the
crankshaft
1
Loosen the two screws (A) and remove
the service cover (8) with the gasket (B)
and the valve (9).
2 Remove damaged welch plug (7).
3
Remove the spring ring (1).
4
Pull off the crank wheel (2) with aid of a
pulling-off device (service tool). Steady
the crank wheel for support.
5
Remove the key (D) from the crank-
shaft (5).
6
Removethespringring(3)andpulloutthe
crankshaft; if necessary, press out the
crankshaft through the opening in the cov-
er with aid of a suitable mandrel.
7 Press the ball bearing (4) off the crank-
shaft.
8
Remove the O-ring (6) from the gear
housing (C).
Detaching the
cylinder and the
connecting rod
1Pull the cylinder (8), the washers (3)
and 4), and the holder (5) from the
gear housing (6).
2Push the cylindrical bolt (7) from the cylin-
der (8) and pull out the connecting rod (1).
3Press the needle bearing (2) from the con-
necting rod (1).
4Pull the percussion body (A) with the gas-
ket (9) from the cylinder (8).
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Repair Instructions No.182.03/98
PBE 6 S
Maintenance
General It is recommended to submit the machine to maintenance after the carbon brushes have switched off.
Cleaning Clean all parts – with the exception of the electrical parts – with cold cleaning agent. Caution! No clean-
ing agent should penetrate into the bearing. Clean the electrical parts with a dry brush.
Check for wear Check the disassembled parts for wear (visual inspection) and replace worn parts.
Electrical tests Before reassembling, perform an electrical test on all relevant parts (see chapter Electrical and Me-
chanical Test Instructions).
Lubrication Each time maintenance is performed, the machine is to be lubricates as stated in the lubrication plan.
After the machine is fully disassembled, completely remove the old grease and replace with new
grease. The grease must be applied to the machine as indicated in the lubrication plan.
Legend
ACover with red grease (60 g)
BCover with blue grease (40 g)
Torques Screws in plastic 2,5 Nm
Screws in metall 4,0 Nm
A
A
A
A
AA
A
A
B
B
A
(45 g)
B
B(30 g)
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Repair Instructions No.182.03/98
PBE 6 S
Assembly
Mounting the
cylinder and the
connecting rod
1Press the needle bearing (2) into the con-
necting rod (1).
2Push the percussion body (A) and the
gasket (9) into the cylinder (8).
3Put together the cylinder (8) and the con-
necting rod (1) and push the cylindrical
bolt (7) through both borings.
4Insert the cylinder (8), the washers (3
and 4) and the holder (5) into the gear
housing (6).
Mounting the
crankshaft 1Insert the O-ring (6) into the gear hous-
ing (C).
2Press the ball bearing (4) onto the crank-
shaft (5).
3Insert the crankshaft (5) into the gear
housing from below (C) and fit it to the
connecting rod bearing.
4Mount the spring ring (3).
5Insert the key (D) into the crankshaft (5).
6Fit the crank wheel (2) with the collar fac-
ing the eccentric and press it on.
☞Steady the crankshaft with a suitable
mandrel which is pushed through the
opening in the cover (otherwise the
crankshaft is pushed in too far).
7Secure the crank wheel (2) with the spring
ring (1).
8If necessary, mount the welch plug (7).
9Fill the gear housing (C) through the serv-
ice opening with grease according to the
lubrication chart.
10Fit the service cover (8) with gasket (B)
and valve (9) and fasten it with the
screws (A).
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Repair Instructions No.182.03/98
PBE 6 S
Mounting the
gear box cover 1Press the needle bearings (4 and 7) into the gear box cover (3).
2Place the insert (5) into the gear box
cover (3) (mind the right position!) and fit
the gasket (6).
3Fitthegearbox cover (3)andfastenit with
the screws (8).
4Insert the grease seal (2) and the
O-ring (1) into the gear box cover (3).
Mounting the
flange 1Insert the spindle sleeve (7) into the hous- ing (6).
2Fit the flange (5) with the ring (8) to the
housing (6) and fasten them with the se-
cured screws (1).
3Mount the O-rings (3 and 4) and the
sleeve (2).
Assembling the
spindle 1Insert the rubber ring (9), the recoil ring (A), the spacer (B), and the grease
seal (C) into the flange (see assembly
step 4).
2Insert the snap die (D) into the tool recep-
tion (8).
3Insert the tool reception (8) completely
with the snap die (D), the spacer (7) and
the O-ring (6) into the gear box.
4Fittheadaptersleeve(2)andfasten it with
the secured screws (1).
5Insert the four balls (3) into the adapter
sleeve (2).
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Repair Instructions No.182.03/98
PBE 6 S
Mounting the
armature 1Push the insulating disk (5) and the ring (7) over the armature shaft and press
on the armature bearings (4) and (8).
2Push the bearing sleeve (3) over the ar-
mature bearing (4).
3Lightly grease the armature bearing (8)
and insert the complete armature into the
machine by turning it.
4Insert the brush holders (C) into the motor
housing (9). Align them with the adjust-
ment tool (service tool) and fix them with
the screws (B).
5Push the field (1) into the motor hous-
ing (9) and insert the air deflector ring (2).
Mind the right position!
6Push the motor housing (9) with the
field (1) and the air deflector ring (2) over
the armature.
7Fasten the motor housing with two short
screws (A) and two long screws (D).
Assembling the
handgrip 1Insert the switch (9) with the capacitor into the handle shell (7).
2Insert the connecting cable (H) with the
cable entry sleeve as well as the cable
clamps (D) into the handle shell (7).
3Fit the handle shell (C) with the holding-
down device to the other handle shell and
fasten them with the four screws (6).
☞Take care that no cables are jammed
or squeezed.
4Insert the handgrip holder (4) and the rub-
ber collar (3) into the handle shell (7).
5Connect according to wiring diagram.
6Insert the damping element (2) into the
housing.
7Push the completed pair of handle shells
over the housing (F) and fasten it with the
screws (G).
8Fasten both Torx screws (8) TX 30 of the
handgrip holder (4) together with the
disks.
9Insert the handle cover (A) from above
and fasten it with the screw (B).
10Screw down the handle screw (E),steady-
ing the knurled nut (5) at the same time.
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Repair Instructions No.182.03/98
PBE 6 S
Mounting the
carbon brushes 1Mount the carbon brushes (3) and mount the cable lugs (h) and (i) on the field.
2Insert the carbon brushes (3) into the
brush holders (4).
3Pull up the brush springs (5) of the brush
holders(4)andpushthemoverthecarbon
brushes (3).
4Fasten the carbon brush covers (2) with
the screws (1).
Mounting the ball
holding device 1Fit the locking bolt (4) together with the ball holding device (5).
2Fit the pressure spring (6) and the retain-
ing plate (2), depress them and insert the
locking levers (3).
3Mount the locking sleeve (1).
Mounting the
auxiliary handle 1Mount the damper (7) and the damping el- ement (8) and secure them with the lock-
ing ring (9).
2Fit the rubber sleeve (A).
3Push back the rubber sleeve (A) and
mount the rubber bushing (5).
4Press the clamping ring (1) and place the
auxiliary handle (4) on the clamping
ring (1).
5Insert the screw (6) through the clamping
ring (1) and the auxiliary handle (4).
6Push the washer (3) over the screw (6).
7Secure the screw (6) with the nut (2).
Test Run
Electrical Test
Test run the machine and pay attention to noises.
Let the machine run-in.
Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).
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