Atlas Copco PB 6S Setup guide

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Repair Instructions No.176.11/96
PB 6S
Special Tools
Required
■ Adjustment tool for carbon brushes 9170 3022 60
■ Pulling-off device 9170 0314 440
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!
Disassembly
Removing the
auxiliary handle
1
Unscrewthenut(2)andremovethewash-
er (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 the locking sleeve (1).
2
Depress the retaining plate (2) against re-
silience - the locking levers (3) are re-
leased. Remove the locking levers (3).
3
Release the retaining plate (2) and re-
move the pressure spring (6).
4
Remove the locking bolt (4) together with
the ball holding device (5).
5
Remove the ball holding device (5) from
the locking bolt (4).
Disassembling
the tool
acceptance
1
Remove all four balls (1) with aid of a mag-
net.
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.176.11/96
PB 6S
Disassembling
the flange
1
Remove the rubber ring (1) and the
sleeve (2).
2
Disassemble the flange (3) as described
below:
Fasten two hardened screws (4) in the
flange (3).
Fasten the machine in a vice.
☞
Do not fasten the machine too tightly
since the gear box would become dis-
torted.
Heat up the gear box (7) where the
flange is located, with a hot air blower.
Insert a flat steel (5) between the two
screws (4) and remove the flange (3).
☞
Attention: left-handed thread!
3
Remove the spindle sleeve (6) with
the washers (A) and (9) as well as the
holder (8).
4
Remove the percussion body (C) with the
O-ring (D) and the gasket (B) from the
spindle sleeve (6), if necessary.
Detaching the
connecting rod
1
Remove the two screws (4) and take off
the service cover (3) with the gasket (2).
2
Remove the connecting rod (7) from the
shaft (5).
3
Pull out the connecting rod (7) together
with the cylinder (8).
4 Remove the cylindrical bolt (1) from the
cylinder (8).
5
Pulloffthebearing(6)fromtheconnecting
rod (7) with aid of an interior extractor.
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Repair Instructions No.176.11/96
PB 6S
Removing the
handle
1
Loosenthetwoscrews(1)andremovethe
housing (2).
2
Loosen the screws (6) and remove the
plate (5).
3
Remove the handle (7) including the
switch(E) (oldmodel), with thelid (D) (soft
grip).
4
Loosen the screw (C) and detach the
lid (D).
5
☞
Only applicable for newer switches:
first lever off the lid, then loosen the top
screw.
6
Remove the rubber stops (8) and (4).
7
Remove the connection cable (F) with the
cable entry sleeve (3) from the switch (E)
and remove the switch from the hand-
grip (7).
8
Loosen the screws (9) and pull off the
guard (B) from the gear box (A).
Removing the
carbon brushes
1
Loosen the screws (1) and remove the
carbon brush covers (2).
2
Lift the respective brush spring from the
carbon brushes (5) and place them on top
of the brush holders.
3
Pull the respective cable lug from the car-
bon brushes (5) and pull out the carbon
brushes.
4
Loosen the four screws (3) and pull off the
motor housing (9) with the electric field (8)
and the air deflector ring (7).
5
Remove the air deflector ring (7).
6
Remove the electric field (8) from the mo-
tor housing (9) (if necessary, hit the motor
housing lightly with a plastic hammer),
watch out for the rubber stops (6) which
might fall out.
7 Remove the carbon brush holders (4).
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Repair Instructions No.176.11/96
PB 6S
Dismantling the
bearing end plate
of the gear box
1
Loosen the screws (4) and (D).
Loosenthe bearing end plate(6) by hitting
the gear box with a plastic hammer and re-
move it.
2
Pull the armature (9) from the bearing end
plate (6) (if necessary, hit the bearing end
plate lightly with a plastic hammer) and re-
move the bearing bush (C) from the ball
bearing (B).
3
Press off the ball bearing (B) and remove
the insulating disc (A).
4
RemovetheO-ring(3) andthewasher(5).
Press off the ball bearing (2) and remove
the seal ring (1).
5 Remove the gasket from the bearing end
plate (6) and take out the insert (7).
6
Pull out the needle bearing (8) with aid of
an interior extractor.
Detaching the
eccentric shaft
1
Remove the locking washer (1).
2
Pull off the toothed wheel (2) with
aid of a pulling off device
(service tool 9170 0314 440).
3
Remove the key (7) from the shaft (5).
4 Remove the locking washer (3) and pull
out the shaft (5); if necessary, press the
shaft through the opening in the gear box
with aid of a suitable mandrel.
5
Press the ball bearing (4) from the shaft.
6
Remove the O-ring (6) from the gear box.
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Repair Instructions No.176.11/96
PB 6S
Maintenance
General It is recommended that maintenance be performed on the machine at regular intervals or when the car-
bon brushes switch off at the latest. When carrying out manitenance, all worn parts must be changed.
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
A Cover with red grease (total 60 g)
B Generously cover with blue grease (total 60 g)
Torques Screws in plastic 2,0 Nm
Screws in metall 3,0 Nm
A AAA
A A
A
A B
B
B
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Repair Instructions No.176.11/96
PB 6S
Assembly
Mounting the
connecting rod 1Press the bearing (5) into the connecting rod (6).
2Fit the O-ring (1) to the percussion
body (2).
3Push the percussion body (2) together
with the gasket (3) into the cylinder (7).
4Fit together the cylinder (7) with the con-
necting rod (6) and put the cylindrical
bolt (4) through the two borings.
Mounting the
eccentric shaft 1Insert the O-ring (A) into the gear box (6).
2Press the ball bearing (4) onto the
shaft (5).
3Insert the cylinder with the connecting rod
(see step 1) into the gear box (6).
4Insert the shaft (5) into the gear box (6)
from below and fix it to the con rod bear-
ing.
5Mount the locking washer (3). Fit the
key (B) to the shaft (5).
6Fit the toothed wheel (2) with the collar
facing the shaft and press it on.
☞Steady the eccentric shaft with a suita-
ble mandrel which is pushed through
the opening in the gear box (otherwise
the shaft gets pushed in too far).
7Secure the toothed wheel (2) with the
locking washer (1).
8Fill the gear box (6) with grease through
the top opening according to the lubrica-
tion chart.
9Fasten the gasket (9) and the service cov-
er (7) with the screws (7).
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Repair Instructions No.176.11/96
PB 6S
Mounting the
bearing end plate
of the gear box
1Press the needle bearing (8) into the bear-
ing end plate (6).
2Place the insert (7) in the bearing end
plate (6) (mind the right position!) and fit
the gasket.
3Push the seal ring (1) over the
armature (9) and press on the needle
bearing (2).
4Mount the O-ring (3) and the washer (5).
5Fit the insulating disc (A) and the ball
bearing (B) to the armature (9).
6Fit the bearing bush (C) to the ball bear-
ing(B) and insert the armature(9) through
the gear box cover (6) turning it.
7Fasten the screws (4) and (D).
Mounting the
carbon brushes 1Insertthecarbonbrushholders(4)intothe
motor housing (9) and screw them down
(do not yet fasten them completely).
Push the adjustment tool (service tool
9170 0232 60) from the outside through
the carbon brush holders (4) and adjust
the carbon brush holders.
2Screw down the carbon brush holders (4)
and remove the adjustment tool.
3Insert both rubber stops (6).
4Insert the field (8) into the motor hous-
ing (9) and fit the air deflector ring (7)
(mind the right position!).
5Fasten the motor housing (9) to the gear
box with the screws (3).
6Fit the cable lugs of the carbon
brushes (5) to the field (8).
7Insert the carbon brushes (5) into the car-
bon brush holders (4).
8Pull up the brush springs of the carbon
brush holders (4) by the hook and push
them over the carbon brushes (5).
9Fasten the carbon brush covers (2) with
the screws (1).
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Repair Instructions No.176.11/96
PB 6S
Mounting the
handle 1Push the guard (B) over the gear box (A) and fasten it with the screws (9).
☞Should the switch (E) be damaged,
replace by a new one
(reversion kit 917 0320 670).
2Connect the cable (F) and the cable entry
sleeve (3) with the switch (E) and mount
them in the handle (7).
3Connect them according to the wiring dia-
gram.
4Mount the rubber stops (8) and (4).
5Fasten the switch (E) to the handle (7)
with screws and mount the lid (D) (soft
grip).
6Fasten the plate (5) with screws (6).
7Push the housing (2) over the gear box.
☞Take care that the contacts in the
housing grasp the gear box contacts.
8Fasten the housing with the screws (1).
Mounting the
flange 1Push the spindle holder (7) and the wash-
ers (8) and (9) over the spindle sleeve (6).
2☞Apply Omnifit 80 to the flange (3) and
screw it down (left-handed thread).
3Fasten two hardened screws (4) in the
flange (3). (They have to be removed be-
fore further assembly.)
Fasten the machine in a vice. Do not fas-
ten the machine too tight since the gear
box would become distorted.
Insert a flat steel (5) between the two
screws (4) and screw down the flange (3).
4Insert the sleeve (2) and the rubber
ring (1) into the flange (3).
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Repair Instructions No.176.11/96
PB 6S
Assembling the
tool acceptance 1Inserttherecoilring(7),thespacer (8)and the O-ring (9) into the flange (see step 6).
2Insert the snap die (A) into the tool accept-
ance (4).
3Insertthe tool acceptance completely with
the snap die (A), the spacer (5) and the
gasket (6) into the gear box.
4Fittheadapter sleeve(2)and fastenit with
the five screws (B).
5Insert the four balls (1) into the adapter
sleeve (2).
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.
Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).
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