Atlas Copco PHE 45 S Setup guide

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Repair Instructions No.189.03/01
PHE 45 S
Special Tools
Require
■ Torx screwdriver TX 1 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.189.03/01
PHE 45 S
Removing
the armature
1
Loosen the four screws (B) and remove
the motor housing cap (A).
2
Remove the respective brush springs (2)
fromthecarbonbrushes(D)andplacethem
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
Removethe bearingbush(9)from the ball
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 (B) steadying
the knurled nut (5) at the same time. Re-
move the knurled nut (5).
2
Loosen the screw (2).
3
Loosen the screw (9) and lever off the soft
grip (8).
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 (D).
Pull off the switch connection wires -
.
6
Remove the switch (C) with handle
shell (6).
7 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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C
DED
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Repair Instructions No.189.03/01
PHE 45 S
Detaching the
damping element
1
Loosenthetwoscrews(4)andremovethe
gear box insulation (2) and (3).
2
Undo both screws (5) of the handgrip
holder (7) and remove them together with
the discs (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.189.03/01
PHE 45 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 Remove the four screws (F). The screws
are very tight, since they were secured
with locking agent.
4
Remove the flange (E).
5 Remove the distance sleeve (6) and the
sleeve (7).
6
☞
Remove both locking levers (C) by de-
pressing the retaining plate (D) against
resilience. Remove the retaining
plate (D).
7
Remove the pressure spring (B).
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 backing flange (A) and the
felt washer (9).
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
Loosen two screws (1) and remove the
cylinder (4) with the percussion body (2)
as well as the seal ring and the O-ring (3)
from the crankcase (5).
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Repair Instructions No.189.03/01
PHE 45 S
Dismantling the
reduction gear
1Loosen two screws (H).
2Removethebearing(G)and thereduction
gear shaft assembly (E).
☞If necessary, expel the reduction gear
shaft assembly (E) with aid of a plastic
hammer.
3Depress the bevel gear (4) with aid of the
(dis-) assembly tool (service tool). Keep it
depressedandremovethelocking ring(5)
with aid of special pliers.
4Remove the bevel gear (4), the ball bear-
ings (3 and F), the needle bear-
ings (7 and 2), the coupling (1), the back-
ing flange (8), the pressure spring (9), the
coupling sleeve (A), the coupling (B), the
balls (C), the indexing sleeve (D) 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 an in-
terior extractor (9) in direction of arrow
(see illustration below).
5Press the pin (6) from the piston (5) and
remove the piston (5).
6Push the needle bearing (8) from the con-
necting rod (7).
D
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Repair Instructions No.189.03/01
PHE 45 S
Maintenance
General It is recommended that maintenance be performed on the machine at regular intervals or when the
carbon brushes switch off at the latest.
Cleaning Clean all parts – with the exception of the electrical parts – with cold cleaning agent. Caution! No
cleaning 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
Mechanical 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 1.8 Nm
Screws in metal 4.0 Nm
Gear box screws 15.0 Nm
■Use locking agent for all metal housing screws!
B
B
B
B
C
B
A
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Repair Instructions No.189.03/01
PHE 45 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), thebackingflange (8),
the pressure spring (9), the coupling
sleeve (A), the coupling (B), the balls (C),
the indexing sleeve (D) 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 bearing (G) on the reduction
gear.
4Insert the reduction gear completely into
the crankcase and fasten it with the two
secured screws (H) (4 Nm).
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Repair Instructions No.189.03/01
PHE 45 S
Assembling
the spindle 1Lightly grease the inner wall of the cylin- der (4) and push it over the piston (O) (the
piston is illustrated on page 7, pos.5, ill. 1).
2Insert the cylinder (4) with the percussion
body (2), as well as the seal ring and the
O-ring (3) into the crankcase (5) and fas-
ten them with the four secured screws (1).
3Insert the O-ring (N), the snap die (M), the
disk(L), the O-ring (K)andthe disk (J) into
the spindle gear (G). Fit the disk (L) with
the phase facing the snap die. Mind the
right position!
4Push the spindle sleeve (7) with the
O-ring (6) over the spindle gear (G).
5Lock the spindle gear with the four
pins (H) using a magnet for support.
6Mountthe needlebearing (B),thedisks (C
and E), the cup springs (D) as well as the
needle bearing (F) in the bearing end
plate (A).
7Mount the locking ring (9) with aid of spe-
cial pliers.
8Insertthe sealring(8) into thebearing end
plate (A).
9Push 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.
2Fit the gasket (2) and the bearing end
plate (1) completely with the spindle
sleeve to the crankcase (8).
3Push the pressure spring (B) and the re-
taining plate (D) over the spindle sleeve
and depress them.
4☞Press in both locking levers (C) from
the side against resilience.
5Push the distance sleeve (6) and the
sleeve (7) over the spindle sleeve.
6Push the flange (E) over the spindle
sleeve (7) and fasten it tightly with the four
secured screws (F) (15 Nm).
7Push over the distance sleeve (4) and the
sleeve (5).
8Mount the cap (3).
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Repair Instructions No.189.03/01
PHE 45 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) and the
damping element (6) into the crankcase.
3Fit the gear box insulations (2) and (3) to
the machine and fasten them with the two
screws (4).
☞Insert the gear box insulations (2) and
(3) at an angle such that the toothings
will interlock properly.
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.189.03/01
PHE 45 S
Mounting the
electric
components
1Insert a sleeve (4) into the handle shell (A)
and fit the handle shell to the motor housing.
2Mount the second sleeve (4) , the elec-
tronic element (1), and the switch
board (C) in the handle (6).
3Wire the switch connections. See illustra-
tionontherightand the circuit diagram
below.
4Lay the connection cable (E) with the pro-
tection cover (F) in the handle shell (6)
and connect it with the switch (C).
5Put the handle (6) with the holding down de-
vice (3) on the other half of the handle (A).
6Fitthesoftgrip (8)andfixitwiththescrew (9).
7Insert the knurled nut (5) into the handle
shell (6).
8Fasten the secured handle screw (B) to
the handle shell (A) while steadying the
knurled nut (5).
9Insert two screws (D) with the discs and
fasten them.
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Electronics
Assembly
Inductor
Boat
WIRING
SCHEMATIC
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Wire
No. Wire Colour from to
110 V 120 V 230 V
1blue white blue mains switch
2brown black brown mains switch
3red red red field guide 9
4red red red field switch
5yellow yellow yellow field brush holder
6black black black black brush holder
7white black black motor control switch
8black black black motor control switch
9black blue red motor control guide 3
Wiring diagram
Circuit diagram

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Repair Instructions No.189.03/01
PHE 45 S
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). Pull the brush springs (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).
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)
andthe switchknob(9) from theoutside in
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).
☞Take care that the pin (7) grasps the
groove in the indexing sleeve (D)
(see page 7, ill. 2, part (D)).
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Repair Instructions No.189.03/01
PHE 45 S
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).
6Pushthe holdingdevice (3)overthe depth
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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