Atlas Copco PN 6000 S Setup guide

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Repair Instructions No.178.06/97
PN 6000 S
Special Tools
Required
■ Torx screwdriverTX 15 4931 599 004
■ Torx screwdriver TX 20 4931 599 005
■ Torx screwdriverbit TX 30 4932 319 998
■ Permanent-magnet holder 4932 315 508
■ Forcing disks 4931 599 021
■ (Dis-)Assembly tool 4931 599 011
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
Detaching the
holding grip
1
Remove the depth gauge (2) with the
holding device (3) from the tool.
2
Remove the holding device (3) from the
depth gauge (2).
3
Remove the holding grip (1).
4
Remove the locking ring (9) with aid of
special pliers and remove the O-ring (8).
5
Remove the plastic holder (7) from the
tool.
6 Remove the pin (4) and the nut (6) from
the clamping plate (5).
7
Slightly bend up the clamping plate (5)
and push it off.
Detaching the
switch knob
1
Remove the four screws (6).
2
Carefully lever off the gear box insula-
tion (3) at the edge using a screwdriver.
3
Remove the O-ring (5) from the gear box
insulation (3). Remove the locking ring (4)
with aid of special pliers.
4 Lever off the switch knob (9) from the out-
side and remove it together with the pres-
sure spring (1) as well as the ball (2).
5 Remove the shift pin (7) and the torsion
spring (8) from the gear box insulation (3).
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Repair Instructions No.178.06/97
PN 6000 S
Removing the
armature
1
Loosen the four screws (B) and remove
the motor housing cap (A).
2
Remove the respective brush springs (2)
from the carbon brushes (D) and place
them on the upper edge of the brush
holder (E).
3
Pull the cable lugs (1) and (C) from the
carbon brushes (D) and pull out the car-
bon brushes.
4
Slightly lift the brush holder (E), unlatch
them (see arrow) and take them out.
5 Remove the armature (6) completely with
the fan (7) from the motor housing (3) by
turning it. If necessary, use a plastic ham-
mer for support.
6
Removethebearingbush(9)fromtheball
bearing (8).
7
Press the ball bearing (8) as well as the
ball bearing (4) from the armature with aid
of the forcing disks (service tool).
8
If necessary, press the fan (7) from the ar-
mature (6).
9
Remove the plug (5) from the armature (6).
Removing the
electric
components
1 Remove the handle screw (C) steadying
the knurled nut (5) at the same time. Re-
move the knurled nut (5).
2
Loosen the screw (9) and lever off the soft
grip (8).
3
Remove the four screws (B) of the handle
shell (A).
4
Remove the handle shell (6) with the hold-
ing-down device (3).
5
Loosen the cable clamp (7) and lay bare
the connection cable (E) with the protec-
tion cover (F).
6
Pull off the switch connection wires (1)
and (2).
7
Remove the switch (D) with the capacitor
from the handle shell (6).
8
Remove the sleeves (4) and the handle
shell (A).
Detaching the
field
1
Remove the motor housing (1) with the
field (2) from the crankcase.
2
Loosenthetwoscrews(3)andremovethe
field (2) from the motor housing. If neces-
sary, use a plastic hammer for support.
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Repair Instructions No.178.06/97
PN 6000 S
Detaching the
damping element
1
Loosenthetwoscrews(4)andremovethe
gear box insulation (2) and (3).
2
Loosen both screws (5) of the handgrip
holder (7) and remove them together with
the disks (6).
3
Remove the handgrip holder (7) and the
damping element (8).
☞
Attention: Do not dismantle the damp-
ing element (8)!
4
Remove the rubber collar (1).
Removing the
crankcase top
cover
1
Lever off the cap (5).
2
Remove the four screws (6).
3 Loosen the screw (4) steadying the crank
gear from below with aid of a screwdriver
(see arrow).
4
Remove the crankcase top cover (3) and
the gasket (7).
5
Remove the locking ring (2) with aid of
special pliers and push out the ball bear-
ing (1).
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Repair Instructions No.178.06/97
PN 6000 S
Detaching the
bearing end plate
1
Lever off the cap (3) with aid of a screw-
driver.
2
Remove the distance sleeve (4) and the
sleeve (5) from the machine.
3
Loosen the four screws (F). They are fas-
tened very tightly.
4
Remove the flange (G).
5 Remove the distance sleeve (6) and the
sleeve (7).
6
☞
Remove both locking levers (D) by
depressing the retaining plate (E)
against resilience. Remove the retaining
plate (E).
7
Remove the pressure spring (C).
8
Remove the bearing end plate (1) com-
pletely with the spindle sleeve from the
crankcase (8).
9
Remove the gasket (2).
10
Remove the locking ring (B) with aid of
special pliers.
11
Remove the backing flange (A) and the
felt washer (9).
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Repair Instructions No.178.06/97
PN 6000 S
Dismantling the
spindle
1
Press the spindle sleeve (7) with the
spindle gear (G) from the bearing end
plate (A).
2
Lever off the seal ring (8).
3
Remove the locking ring (9) with aid of
special pliers.
4
Remove the needle bearing (B), the disks
(C and E), the cup springs (D) as well as
the needle bearing (F) from the bearing
end plate (A).
5 Remove the four pins (H) with aid of a
magnet.
6
Remove the spindle sleeve (7) with the
O-ring (6) from the spindle gear (G).
7
Remove the O-ring (N), the snap die (M),
the disk (L), the O-ring (K) and the disk (J)
from the spindle gear (G).
8
Loosenthetwoscrews(1)andremovethe
cylinder (4) with the percussion body (2)
and the O-ring (3) from the crankcase (5).
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Repair Instructions No.178.06/97
PN 6000 S
Dismantling the
reduction gear 1Loosen the two screws (K) and pull the in- dexing sleeve (H) completely from the
crankcase (6).
2Remove the bearing (J) and the indexing
sleeve (H).
3Press down the bevel gear (4) with aid of
the disassembly tool (service tool).
4Keepitdepressedandremovethelocking
ring (5) with aid of special pliers.
5Remove the bevel gear (4), the ball bear-
ings (3 and F), the needle bearings (7
and 2), the coupling (1), the backing
flange (8), the pressure spring (9), the
coupling sleeve (A), the coupling (B), the
balls (C), the indexing sleeve (D) as well
as the pinion (G) from the reduction gear
shaft (E).
Dismantling the
crank assembly 1Turn the crank gear (3) until the piston (5)
is located in the back dead centre.
2Slightly lift the connecting rod (7).
3Turn the crank gear (3) until it can be re-
moved from the crankcase (1). Remove it
together with the connecting rod (7), com-
pletely with piston (5) and O-ring (4).
☞Do not apply any force! Do not jam the
piston (5) and the connecting rod.
4Pull out the needle bearing (2) with aid of
an interior extractor.
5Press the pin (6) from the piston (5) and
remove the piston (5).
6Push the needle bearing (8) from the con-
necting rod (7).
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Repair Instructions No.178.06/97
PN 6000 S
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.
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
Distribute the grease type N (125 g) from the maintenance set as follows:
A Thinly daub
BGenerously cover
CFill with 43 g grease
DFill with 28 g grease
Torques Screws in plastic 2,5 Nm
Screws in metal 4,0 Nm
Gear box screws 15,0 Nm
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B
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C
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Repair Instructions No.178.06/97
PN 6000 S
Assembly
Assembling the
crank assembly 1Mount the needle bearing (8) in the con- necting rod (7).
2Push the piston (5) over the connecting
rod (7) and mount the pin (6).
3Presstheneedlebearing(2)intothecrank
gear.
4Insert the crank gear (3), the connecting
rod (7), the piston (5) and the O-ring (4)
into the crankcase (1). Mind the right posi-
tion!
Turn the crank gear (3) until the piston (5)
is located in the back dead centre.
☞Do not apply any force! Do not jam the
piston (5) and the connecting rod.
Assembling the
reduction gear 1Push the bevel gear (4), the ball bear-
ings (3 and F), the needle bearings (7
and 2), the coupling (1), the backing
flange (8), the pressure spring (9), the
coupling sleeve (A), the coupling (B), the
balls (C), the indexing sleeve (D) as well
as the pinion (G) over the reduction gear
shaft (E) as shown in illustration.
☞Fix the single balls (C) with grease.
2Depress the bevel gear (4) with aid of the
assembly tool (service tool).
Keep it depressed and mount the locking
ring (5) with aid of special pliers.
3Mount the indexing sleeve (H) with the
boring facing downward.
4Mount the bearing (J) on the reduction
gear.
5Insert the reduction gear completely
withthe indexing sleeve (H) intothecrank-
case and fasten it with the two secured
screws (K).
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Repair Instructions No.178.06/97
PN 6000 S
Assembling the
spindle 1Insert the cylinder (4) with the percussion body (2) and the O-ring (3) into the crank-
case(5)and fastenitwiththe foursecured
screws (1).
2Insert the O-ring (N), the snap die (M), the
disk(L),theO-ring(K)andthedisk(J)into
the spindle gear (G). Fit the disk (L) with
the phase facing the snap die. Mind the
right position!
3Push the spindle sleeve (7) with the
O-ring (6) over the spindle gear (G).
4Lock the spindle gear with the four
pins (H) using a magnet for support.
5Mounttheneedlebearing (B), thedisks(C
and E), the cup springs (D) as well as the
needle bearing (F) in the bearing end
plate (A).
6Mount the locking ring (9) with aid of spe-
cial pliers.
7Insertthesealring(8) into the bearingend
plate (A).
8Push the spindle sleeve (7) with the spin-
dle gear (G) into the bearing end plate (A).
Mounting the
bearing end plate 1Push the backing flange (A) and the felt
washer (9) over the spindle sleeve.
2Mount the locking ring (B) with aid of spe-
cial pliers.
3Fit the gasket (2) and the bearing end
plate (1) completely with the spindle
sleeve to the crankcase (8).
4Push the pressure spring (C) and the re-
taining plate (E) over the spindle sleeve
and depress them.
5☞Press in both locking levers (D) from
the side against resilience.
6Push the distance sleeve (6) and the
sleeve (7) over the spindle sleeve.
7Push the flange (G) over the spindle
sleeve (7) and fasten it tightly with the four
secured screws (F) (15 Nm).
8Push over the distance sleeve (4) and the
sleeve (5).
9Mount the cap (3).
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Repair Instructions No.178.06/97
PN 6000 S
Mounting the
crankcase
top cover
1Press the ball bearing (1) onto the crank
gear.
2Mount the locking ring (2) with aid of spe-
cial pliers.
3Fit the crankcase top cover (3) and the
gasket (7) to the crankcase.
4Fasten the screw (4) from below with aid
of a screwdriver by steadying the crank
gear (see arrow).
5Fasten the crankcase top cover (3) with
the four screws (6).
6Fit the cap (5) to the crankcase top cov-
er (3).
Mounting the
damping element 1Insert the rubber collar (1) into the crank-
case.
2Insert the handgrip holder (5) as well as
the damping element (6) into the crank-
case.
3Fit the gear box insulations (2) and (3) to
the machine and fasten them with the two
screws (4).
Mounting the
field 1Insert the field (2) into the motor housing. Mind the right position!
2Fasten the field (2) with the two
screws (3).
3Fit the motor housing (1) with the field (2)
to the crankcase.
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Repair Instructions No.178.06/97
PN 6000 S
Mounting the
electric
components
1Insertasleeve(4)intothe handle shell (C)
and fit the handle shell to the motor hous-
ing.
2Mount the other sleeve (4), the switch (F)
and the capacitor in the handle shell (6).
3Connect the switch connection wires (1
and 2) with the field.
4Lay the connection cable (G) with the pro-
tection cover (H) in the handle shell (6)
and connect it with the switch (F).
5Fit the handle shell (6) with the holding-
down device (3) to the handle shell (C)
and fasten them with the four screws (D).
6Fit the soft grip (A) and fix it with the
screw (B).
7Insert the knurled nut (5) into the handle
shell (6).
8Fasten the secured handle screw (E) to
the handle shell (C) while steadying the
knurled nut (5).
9Insert the screws (9) with the washers (8)
and fasten them.
Mounting the
armature 1Push the plug (5) over the armature (6)
and press the fan (7) onto the arma-
ture (6). Press the ball bearing (8) as well
as the ball bearing (4) over the armature.
Push the bearing bush (9) over the ball
bearing (8).
2Insertthearmature (6)completelywiththe
fan (7) into the motor housing (3) by turn-
ing and at the same time depressing it.
3Insert the brush holder (E) into the motor
housing from the side (3) (mind the right
position!) and fasten them.
4Insert the carbon brushes (D) with the
cable lugs (1) and (C) into the brush hold-
er (E).
5Connect the cable lugs (1) and (C) with
the field.
6Mount the brush springs (2) in the brush
holder(E).Pullthebrushsprings(2)aside
at their hooks and pull them over the car-
bon brushes (D).
7Fit the motor housing cap (A) and fasten it
with the four secured screws (B).
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Repair Instructions No.178.06/97
PN 6000 S
Mounting the
switch knob 1Fit the torsion spring (8) to the shift pin (7) such that it is located in the boring of the
shift pin (7).
2Insert the shift pin (7) with the torsion
spring (8) into the gear box insulation (3).
3Mount the ball (2), the pressure spring (1)
andtheswitchknob(9) from the outsidein
the gear box insulation (3).
4Insert the O-ring (5) into the gear box insu-
lation (3) and mount the locking ring (4)
with aid of special pliers.
5Fit the gear box insulation (3) to the
machine and secure it with the four
screws (6).
Mounting the
holding grip 1Push the clamping plate (5) over the neck
of the machine.
2Insert the nut (6) into the clamping
plate (5).
3Push the pin (4) through the clamping
plate (5) and the nut (6).
4Fit the plastic holder (7) to the machine
and secure it with the O-ring (8) and the
locking ring (9).
5Screw down the holding grip (1).
6Pushtheholdingdevice (3)overthedepth
gauge (2).
7Fit the depth gauge (2) with the holding
device (3) to the machine (see arrow in il-
lustration).
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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