Atlas Copco PHE 6 H Setup guide

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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
Special Tools
Required
■ Torx screwdriver TX 30 4932 319 998
■ Forcing disks 4931 599 018
■ Adjustment tool for carbon brushes 9170 302 270
■ Pulling-off device 9170 314 440
■ Tool for dis-/assembly of the spindle (PHE 6 H) 9170 302 260
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!
■
Before disassembly, the machine must be connected to the RTR-READER (maintenance measuring in-
strument) in order to check for a possible maintenance interval.
Disassembly
PHE 6 S:
Dismantling the
tool reception
1
Remove the auxiliary handle (G) com-
pletely with the clamping ring (F).
2
Push back the rubber cover (2) and re-
move the end cover cap (1).
3
Remove the spring ring (3).
4
Remove the stop (4), the rubber stop (5)
and the retainer (6).
5
Depress the retention plate (8) against re-
silience - the latches (7) are relieved. Un-
screw the latches (7) and remove them
(see illustration 1).
6 Remove the retention plate (8), the
spring (L) and the washer (K).
7
Take out the restrictor (J).
8
Remove the cone (H).
9
Loosen the bearing bolt (9). Keep the ten-
sion and carefully remove the clamping
ring (E).
10
Peel off the connecting ring (D).
11
Unscrew both screws (B). Slightly lift the
switch lever (C) and pull out the retaining
strap (A). Remove the switch lever (C).
PHE 6 H:
Dismantling the
tool reception
1 Remove the auxiliary handle (C) com-
pletely with the clamping ring ring (B).
2
Remove the dust guard cap (3).
3
Expelthelatch(8)fromthenosepiecewith
aid of a mandrel.
4
Remove the latch (5), the spring (4) and
the distance sleeve (6).
5
Take out the restrictor (1).
6
Pull off the cone (2).
7
Loosen the bearing bolt (9). Keep the ten-
sion and carefully remove the strap (A).
8
Peel off the connecting ring (7).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 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)off thecarbon
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.181.03/98
PHE 6 H / PHE 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 thebrush
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).
PHE 6 S:
Detaching the
spindle sleeve
1
Loosen both screws (6) and remove the
back part of the plastic housing (7).
2
Remove the plastic housing (8).
3
Fix the machine in a vice provided with
protective chops and remove the nose-
piece (1) (SW 50).
☞
Attention! The nosepiece (1) has a left-
handed thread!
4
Press the rotary shaft seal (2) from the
nosepiece (1).
5
Remove the complete spindle sleeve (5)
from the housing. If necessary, hit the
housing lightly with a plastic hammer to
loosen the drill spindle.
6
Remove the spring ring (3) and press off
the bearing (4).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Detaching the
bearing housing
1
Loosen both screws (4) and remove the
back part of the plastic housing (5).
2
Remove the plastic housing (1).
3
Loosen the screws (3) and remove the
nosepiece (2).
4
Loosen the screws (9) and remove the
bearing housing (8) with the O-ring (7).
5 Press the rotary shaft seal (6) from the
bearing housing (8).
PHE 6 S:
Dismantling the
spindle sleeve
1
Inserta screwdriver(1) into oneof thefour
service borings to lever off the round wire
ring (6). The screwdriver must remain in
the boring. Use a second screwdriver to
lever off the round wire ring through the
other service borings.
2
Take out the retainer (4) and remove the
O-ring (5).
3
Remove the recoil ring (2) and the rubber
ring (3).
4
Push out the anvil (7) with aid of a screw-
driver from the other side of the spindle
sleeve and remove the O-rings (8) from
the anvil.
5
Knock out the buffer (9) through the
grooves (A) in the spindle sleeve with aid
of a mandrel.
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Separating the
driver from the
barrel
1Fix the service tool (4) in a vice (5).
2Insert the driver (2) with the barrel (1) into
the service tool (4) and unscrew the driv-
er (2) from the barrel (1) with aid of an Al-
len key (3).
PHE 6 H:
Dismantling the
spindle sleeve
1Remove the spring ring (1) and press off
the ball bearing (2).
2Remove the spring ring (3).
3Fix the driver (4) in a vice with the anvil up
and knock out the tension ring (A) with aid
of a mandrel.
4Removethe seal rings (8), thering(7) and
the rubber ring (6) from the anvil (9).
5Removetheretainer(5)andtheO-ring(C)
from the barrel (B).
PHE 6 S:
Dismantling the
guide sleeve
1Remove the disk (7). Loosen the four se-
cured screws (6).
2Lever off the guide sleeve (5) from the ma-
chine. If necessary, hit the housing lightly
with a plastic hammer for support.
3Remove the washer (4).
4Remove the spring (3) and the disk (2)
and press out the ring (1).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Detaching the
bevel gear
1Knock the bevel gear (1) from the gear
housing (3) with aid of a mandrel (lead the
mandrel through the opening in the hous-
ing).
2Remove the bearing (2) with aid of a pull-
ing-off device or knock the housing with
the opening against a wooden supporting
plate.
PHE 6 S:
Detaching the
rotary stop
1Remove the following parts, hitting the
side of the machine lightly with a hammer
for support:
- locking ring (6) and
- sleeve (5)
2Detach the spring ring (3) from the
sleeve (5) and remove the rings (2 and 4)
and the spacer (1).
PHE 6 S:
Detaching the
cylinder
1Remove the cylinder (5) from the housing
by hitting the front part of the housing light-
ly with a plastic hammer.
2Remove the spring ring (3).
3Remove the spring washer (2).
4Remove the bevel gear (4) with the bear-
ing (1).
5Pull the bearing (1) from the bevel
gear (4).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
Detaching the
pinion shaft 1Lever off the O-ring (1) and the seal (2).
2Loosen the six screws (H) of the gear
box cover (3) and remove the gear box
cover (3) with the gasket (5).
3Pull out the needle bearings (4) and (G)
with aid of an interior extractor.
4Bend down the lugs of the securing
plate (8).
5Block the drive (A) using a screwdriver
and unscrew the clutch (6) (right-handed
thread).
6Remove the cup spring (7), the securing
plate (8), the drive (A), the friction disk (9)
and the clutch (B).
7Remove the spring ring (C).
8Pull out the pinion (F) with the bearing (D).
☞Fix the end of the pinion shaft in a vice
between protective chops and hit the
housing lightly with a plastic hammer.
9Press the bearing (D) from the pinion (F).
10Remove the O-ring (E) from the motor
housing (pillow block).
Detaching the
crankshaft 1Loosen the two screws (A) and remove
the service cover (8) with the gasket (B)
and the valve (9).
2Remove damaged welch plug (7).
3Remove the spring ring (1).
4Pull off the crank wheel (2) with aid of a
pulling-off device (service tool). Steady
the crank wheel for support.
5Remove the key (D) from the crank-
shaft (5).
6Removethespringring(3)andpull outthe
crankshaft; if necessary, press out the
crankshaft through the opening in the cov-
er with aid of a suitable mandrel.
7Press the ball bearing (4) off the crank-
shaft.
8Remove the O-ring (6) from the gear
housing (C).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
Detaching the
piston and the
connecting rod
1Pull the piston (3) from the gear hous-
ing (7).
2Pull the striker (1) from the piston (3) and
remove the O-ring (2) from the striker (1).
3Press the cylindrical bolt (4) from the pis-
ton (3) and pull out the connecting rod (5).
4Press out the needle bearing (6) from the
connecting rod (5).
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).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
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
AGenerously
BFill
CApply a small amount
Torques Screws in plastic 2,5 Nm
Screws in metal 4,0 Nm
Nut PHE 6 S (see assembly step 8) 120,0 Nm
Driver PHE 6 H (see assembly step 10) 30,0 Nm
Blue grease(80 g)
Mobil HP 22
PHE 6 S
PHE 6 H
B
A
B
Red grease (80 g)
Mobil SHC 007
Red grease (80 g)
Mobil SHC 007
Blue grease (80 g)
Mobil HP 22
A
A
A
A
A
A
B
B
A
A
C
C
AACC
BC
A
A
A
B
C
A
A
B
A
AAA
A
A
A
B
AA
CC
BC
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
Assembly
PHE 6 S:
Mounting the
cylinder
1Press the bearing (1) onto the bevel
gear (4). Fit the spring washer (2) and
secure it with the spring ring (3).
2Insert the bevel gear (4) completely with
the bearing (1) flush into the housing.
3Insert the cylinder (5) into the housing as
far as it will go.
PHE 6 H:
Mounting the
bevel gear
1Press the bevel gear bearing (2) into the
bevel gear (1).
2Press the bevel gear (1) flush with the
bearing (2) into the gear housing (3) using
a suitable mandrel for support.
Mounting the
piston and the
connecting rod
1Press the needle bearing (6) into the con-
necting rod (5).
2Push the striker (1) with the O-ring (2) into
the piston (3).
3Put together the piston (3) and the con-
necting rod (5) and push the cylindric
bolt (4) through both borings.
4Insert the piston (3) with the connecting
rod (5) into the gear housing (7).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
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.181.03/98
PHE 6 H / PHE 6 S
Mounting the
reduction
gear shaft
1Insert the O-ring (E) into the housing.
2Press the bearing (D) onto the pinion (F).
3Press the pinion (F) with the bearing (D)
into the housing.
4Insert the spring ring (C).
5Push the following parts over the pin-
ion (F):
- clutch (B),
- drive (A),
- friction disk (9) (the covering must face
- the drive),
- securing plate (8) ,and
- cup spring (7) (the bulging must face
- the clutch).
6Block the drive (A) against twisting and
screw down the clutch (6) as follows:
Applyatorquewrenchwith a32 mmnut to
the clutch (6) with pressure such that the
resilience is overcome. Screw down the
clutch (6).
☞Torque 3 Nm, use screw locking de-
vice.
7Bend the three lugs of the securing
plate (8) in order to secure the clutch (6).
8Press the needle bearings (4) and (G) into
the gear box cover (3).
9Fit the gear box cover (3) with the
gasket (5)tothehousingand fastenit with
the six screws (H).
10Insert the O-ring (1) and the seal (2) into
the housing.
PHE 6 S:
Mounting the
rotary stop
1Fit the rings (4 and 2) and the spacer (1)
to the sleeve (5) and secure it with the
spring ring (3).
2Push the sleeve (5) over the cylinder (7)
inside the housing.
3Fit the locking ring (6) to the sleeve (5) in-
side the housing (mind the right position!)
and insert them as far as they will go with
aid of a suitable mandrel.
☞The relief (7) of the locking ring (6) for
the switch must face down (see illus-
tration).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 S:
Assembling the
spindle sleeve
1Press the buffer (1) into the spindle
sleeve (9) using a mandrel. Mind the
right position!
2Fit the O-rings (2) to the anvil (3) and in-
sert the anvil into the spindle sleeve (9).
3Insert the following parts into the spindle
sleeve (9):
- recoil ring (4),
- rubber ring (5),
- retainer (6),
- O-ring (7) and
- spring ring (8).
☞Whenmounting thespring ring(8) take
care that it engages in the groove of
the spindle sleeve.
PHE 6 S:
Mounting the
guide sleeve and
the spindle
1Push the spring (F), the washer (6) and
the bearing (B) as well as the O-ring (7)
over the cylinder (E).
2Fit the guide sleeve (8) with the O-ring (9)
and fasten it with the secured screws (A).
3☞Take care that the spring (F) is located
centrally on the cylinder (E) (see illus-
tration).
4Push the ball bearing (5) over the spindle
sleeve (G) and secure it with the spring
ring (4).
5Insert the complete spindle into the hous-
ing.
6Press the rotary shaft seal (3) into the
nosepiece (2).
7Fix the machine into a vice provided with
protective chops and fit the nosepiece (2).
Fasten the nosepiece with a torque of
120 Nm.
☞Attention: The nosepiece (2) has a left-
handed thread!
8Mount the plastic housing (1).
9Fit the back part of the housing (D) and
fasten it with the screws (C).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Assembling the
spindle sleeve
1Insertanew O-ring(C) intotheretainer (5)
and fit the retainer to the barrel (B).
2Grease the anvil (9) and fit two new seal
rings (8).
☞Take care that the seal rings are not
twisted.
3Fit the ring (7) and the rubber ring (6) to
the anvil (9).
4Insert the anvil (9) into the driver (4).
5Mount the spring ring (3).
6Press the ball bearing (2) onto the driv-
er (4) and secure it with the spring ring (1).
PHE 6 H:
Assembling the
driver and the
barrel
1Grease the barrel (1) and screw down the
driver (2).
2Fix the service tool (4) in a vice (5).
3Insert the barrel (1) and the driver into the
service tool and fasten the two with an Al-
len key (3) (30 Nm).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Mounting the
bearing housing
1Press the rotary shaft seal (6) into the
bearing housing (8).
2Fit the bearing housing (8) with the
O-ring (7) to the gear housing and
fasten it with secured screws (9).
3Fit the nosepiece (2) to the bearing
housing (8) and fasten it with secured
screws (3).
4Push the plastic housing (1) over the gear
housing from the front and secure it with
the connecting ring.
5Push the back part of the housing (5) over
thegear housing frombehind and fasten it
with the screws (4).
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).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
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.
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).
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Repair Instructions No.181.03/98
PHE 6 H / PHE 6 S
PHE 6 H:
Assembling the
tool reception
1Insert the connecting ring (7).
2Push the strap (A) over the neck of the
machine and tighten it with the bearing
bolt (9).
3Mount the cone (2) and insert the restric-
tor (1).
4Insert the latch (8) into the nosepiece.
5Insert the distance sleeve (6) and the
spring (4).
6Knock in the latch (5) with light hammer
blows until it is flush with the nosepiece.
PHE 6 S:
Assembling the
tool reception
1Insert the switch lever (C) such that it
grasps the provided groove.
2Slightly lift the switch lever (C), push the
retaining strap (A) under it and fasten it
with the two Allen screws (B).
3Mount the connecting ring (D).
4Push the strap (E) over the neck of the
machine and tighten it with the bearing
bolt (9).
5Mount the cone (H) and insert the restric-
tor (J).
6Mount the washer (K), the spring (L) and
the retention plate (8).
7Depress the retention plate (8) against re-
silience and insert the latches (7) at the
sides.
8Fit the retainer (6), the rubber stop (5) and
the stop (4).
9Mount the spring ring (3).
10Fittherubber cover(2)and pushdownthe
end cover cap (1).
11Mount the auxiliary handle (G) completely
with the clamping ring (F).
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).
1
8
4
3
2
9
A
5
B
6
C
7
15
9
1
654
32
7 8
C B
A
D
F
G
HJ
KL
E
16