Atlas Copco PHE 50 S Setup guide

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Repair Instructions Nr.183.09/00
PHE 50 S
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Special Tools
Require
■ Cone 4931 599 089
■ Forcing disks 4931 599 018
■ (Dis-) Assembly tool 4931 599 011
■ Allen key, long 4931 599 010
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 dismantling, the machine must be connected to RTR-READER (maintenance measuring in-
strument) to check for a possible maintenance interval.
Disassembly
Detaching
the trigger
1
Loosen the screw (8) and remove the trig-
ger (7) with cover.
2
Loosen both screws (1) and remove the
motor cover (2).
3
Loosen the screws (3) and (5) and the dis-
tance sleeve (6).
4
Remove the complete handle (4).
Dismantling the
auxiliary handle
1
Loosenthescrew(2),removethefantype
lock washer (1) and unscrew the han-
dle (3).
2 The following parts must be removed:
- screw off the clamping ring (4)
- support (5)
- push out the plastic cover (8),
- screw (7),
- clamping ring (6),
- depth gauge (9).
3
Push back the sleeve (B) and lever off the
cover cap (A).
4
Remove the sleeve (B).
5 Pull the gear housing insulation (C) from
the machine.
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Repair Instructions Nr.183.09/00
PHE 50 S
Detaching the
electric
components and
the Softgrip
1
On both sides, loosen the screws (4) and
remove the cover (3).
2
Loosen the screw (A).
3
Lever off the Softgrip (8) from above since
it is fitted at the top (see arrow in illustra-
tion).
4
Loosen the screws (6) and detach the ca-
ble clamp (5).
5 Lay bare the connection cable (9) with the
switch(7).Branchofftheconnectioncable
from the switch (7). Pull the cable clamp
off the switch (7).
6
Loosen the screw (1) and detach the serv-
ice LED-module (2).
Detaching the
locking elements
1
Remove the spring ring (1) with aid of spe-
cial pliers. If necessary, use a screwdriver
for support.
2
Remove the stop (2) and the damper
ring (3).
3
Remove the retainer (4).
4
Push in the plate (5) against resilience -
the locking elements (6) are relieved.
Unscrew and remove the locking ele-
ments (6).
5
Relieve the plate (5) and remove the pres-
sure spring (7).
6 Rotate the machine by 90° to remove the
disc (8) (the disc (8) will fall out).
7
Remove the bearing sleeve (9) and the
O-ring (A).
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Repair Instructions Nr.183.09/00
PHE 50 S
Removing the
field and the
armature,
Removing the
gear cover
1
Pull off the respective cable lugs (1) and
remove the carbon brushes (2) on both
sides by lifting the carbon brush springs.
2
Loosen the screws (A) and detach the
brush holders (3).
3
Loosen the four screws (4).
4
Remove the field together with the motor
housing (9).
The armature (5) will remain in the gear
cover (6).
5
Remove the O-ring (B) from the rubber
sleeve of the armature bearing. Pull out
the armature (5) manually, if necessary
use a plastic hammer for support (light
blows).
6
Undo the two screws (7) in the gear
cover (6) and pull off the gear cover (6).
If needed, remove it with blows with a
plastic hammer.
Removing the
complete sleeve
1
Remove the two springs (5) and (6), the
spring ring (7), the actuator (8) and the
O-ring (9).
2
Remove the five screws (3) with their
washers and pull the housing (4) from the
gear housing (B) (the screws are stuck in).
3 Remove the complete spindle sleeve (A).
Remove the O-ring (C).
4
Loosen both screws (1) and remove the
spring (2).
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Repair Instructions Nr.183.09/00
PHE 50 S
Dismantling
the sleeve
1
Remove the locking ring (1) and the re-
taining ring (2).
2
Remove the six balls (4) with aid of a mag-
net from the drill spindle (3) and pull the
drill spindle (3) from the spindle sleeve (F).
3
Remove the anvil (7) from the drill spin-
dle (3) and remove the seals (8) from the
anvil (7).
Expel the distance sleeve (6) from the drill
spindle (3) with aid of a screwdriver (apply
it at the side through the groove).
Remove the O-ring (5) from the drill spin-
dle (3).
4
Remove the following parts from the spin-
dle sleeve (F):
ring (9),
rubber ring (A),
ring (B).
5
Remove the O-ring (C)
and the locking ring (D)
from the spindle sleeve (F),
and press off the ball bearing (E)
with aid of a service tool.
6
Remove the striker (U) from the spindle
sleeve (F) and remove the O-ring (V) from
the striker (U).
7
Detach the locking ring (T) from the spin-
dle sleeve (F).
Remove the following parts:
driver (S),
sleeve (M),
spring (L),
spring ring (K),
sleeve (I),
washer (H),
sleeve (G).
8
Remove the ring (R) from the driver (S).
9
Remove the following parts from the
sleeve (M):
locking ring (Q),
discs (N), (P),
sleeve (O).
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Repair Instructions Nr.183.09/00
PHE 50 S
Detaching
the armature
1
Pull the rubber sleeve (1) and the bearing
ring (6) from the armature (4).
2
Press off the bearings (5) and (2) with aid
of the forcing discs (service tool).
Detach the seal ring (3).
Detaching
the field
1 Remove the air deflector ring (4) from the
motor housing (1).
2
Loosenboth screws (3) with their washers
and expel the field (2) from the motor
housing (1).
Detaching
the bearings
1
Remove the O-ring (6) and the fan type
lock washer (5) as well as the O-ring (3)
from the gear cover (1).
2
Pullout the bearings (2) and (4) with aid of
an interior extractor.
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Repair Instructions Nr.183.09/00
PHE 50 S
Detaching
the crank
1
Apply specially cut pliers between gear
wheel and gear housing (3) to remove the
locking ring (1).
2
Remove the complete crank (2) from the
gear housing (3).
3
Remove the piston and the connecting
rod.
Removing the
connecting rod
1
Remove the four-lips-seal-ring (1) from
the piston (2).
2
Press the bolt (3) from the piston (2) and
pull out the connecting rod (5).
3
Press the bearing (4) from the connecting
rod (5).
Dismantling
the drive
1
Align the drive wheel (4) with the borings
of the screws (7).
Loosen both screws (7) and remove the
complete drive.
2
Remove the spring ring (1) with aid of the
disassembly tool (service tool), depress-
ing the spring plate (2) at the same time.
3
Remove the spring plate (2), friction
disc (3), drive wheel (4), friction disc (5),
spring plate (6), and spacer (B) from the
pinion (A).
4
Pressofftheballbearing (9)with aidof the
forcing discs (service tool).
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Repair Instructions Nr.183.09/00
PHE 50 S
Detaching the
bevel wheel 1Remove the bevel wheel (9) and the bear- ing (8).
2Undo the four nuts (1), remove the wash-
ers (2) and detach the cover (3) as well as
the gasket (4).
Remove the felt ring (A).
3Remove the O-rings (5) and (6) and the
two pins (7).
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
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.
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Repair Instructions Nr.183.09/00
PHE 50 S
Legend
ACover with grease DARINA (total of 50 g) (4931 622 229)
B Cover with blue grease Mobilith HP 222 (40 g total) (9170 304 322)
C Cover with Tivela Compound A (10 g) (493170 215 436)
Torques Screws in plastic 1,5 Nm
Screws in metal 4,0 Nm
Motor housing screws (1) 4,0 Nm
Flange screws gear (2) 10,0 Nm
Screw locking
device Secure all screws with locking device Loctite 222.
30 g
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B
A
CA
C
A
2
AB
B
B
A
C
C
A
30 g
A
10 g
C
A
3 Nm
10 g
A
A
B
B
3 Nm
B
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lightly grease

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Repair Instructions Nr.183.09/00
PHE 50 S
Assembly
Mounting the
bevel wheel 1Press the bearing (2) flush into the gear housing (6).
Press the bevel wheel (1) into the bear-
ing (2).
2Mount the O-rings (4) and (5) and press in
the two pins (3).
3Insert the O-ring (7) into the groove of the
gear housing.
Assembling
the drive 1Press the ball bearing (9) onto the pin- ion (A) and mount the following parts one
after the other on the pinion (A):
spacer (B),
plate (8)
spring plate (6),
friction disc (5),
drive wheel (4),
friction disc (3),
spring plate (2).
☞Lightly grease discs (3) and (5) with
blue grease, type Mobilith HP 222.
2Mount the spring ring (1), depressing the
spring plate (2) at the same time.
3Insert the assembled drive into the gear
housing (C) and fix it with screws (7)
through the aligned plate (8).
☞Cover the screws (7) with screw lock-
ing device and tighten with 2 Nm.
☞Thesafety clutch can't beadjusted:In
case the drill bit does not rotate at low
load, please check the spring plates
and the clutch discs for wear. If neces-
sary, replace them.
Mounting the
connecting rod 1Mount the four-lips-seal-ring (1) to the pis- ton (2).
2Press the bearing (4) into the connecting
rod (5).
3Push the connecting rod (5) into the pis-
ton (2) and secure it with the bolt (3).
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Repair Instructions Nr.183.09/00
PHE 50 S
Mounting
the crank 1Insert the piston and the connecting rod into the gear housing (3).
2Insert the complete crank (2) into the gear
housing (3) from below and hang it in the
connecting rod.
3Insert the locking ring (1) with aid of spe-
cially cut pliers between toothed wheel
and gear housing (3).
☞The locking ring (1) must cover the bor-
ing (4) (dotted line) to avoid the escap-
ing of any grease.
Mounting
the bearings 1Press in the bearings (2) and (3).
2Insert the fan type lock washer (4) and the
O-ring (5) into the gear cover (1).
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Repair Instructions Nr.183.09/00
PHE 50 S
Mounting
the field 1Insert the field (2) into the motor hous- ing (1) (mind the right position!) and se-
cure it with screws (3) and washers
(tightening moment = 8 Nm).
2Fit the air deflector ring (4) on the motor
housing (1).
Mounting
the armature 1Mount the seal ring (3) on the armature shaft.
Press in the bearings (5) and (2).
2Mount the rubber sleeve (1) and the bear-
ing ring (6) on the armature shaft (4).
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Repair Instructions Nr.183.09/00
PHE 50 S
Assembling
the sleeve 1Press the ball bearing (E) onto the spindle sleeve (F) and fit the locking ring (D) and
the O-ring (C).
2Mount the ring (R) on the driver (S).
3Mount the following parts on the
sleeve (M):
disc (N),
sleeve (O),
disc (P).
Insert the locking ring (Q).
4Mount the following parts on the spindle
sleeve (F):
spring ring (K),
sleeve (G),
spring(L)(pressedoverthetoothingofthe
spindle sleeve (F)),
washer (H),
sleeve (I),
sleeve (M),
driver (S).
☞Mount the locking ring (T) on the spin-
dle sleeve (F) with aid of the cone
(service tool).
5MounttheO-ring (V) on the striker (U) and
insert the striker (U) into the spindle
sleeve (F).
☞The O-ring (V) must face the direction
of the four-lips-seal-ring of the piston.
6Insert the ring (B), the rubber ring (A) and
the ring (9) into the spindle sleeve (F).
7Fit the O-ring (5) on the drill spindle (3), in-
sert the distance sleeve (6) into the drill
spindle (3), and fit the seals (8) on the an-
vil (7).
Insert the anvil (7) into the drill spindle (3).
8Insert the drill spindle (3) into the spindle
sleeve (F).
Insert the six balls (4) with aid of a magnet
into the drill spindle (3).
9Mount the locking ring (1) and the retain-
ing ring (2) on the drill spindle (3).
☞Mind the right position of the locking
ring (D) concerning the relieves in the
retaining ring (2).
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Anvil fitting position:
The shortened phase faces the drill
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Repair Instructions Nr.183.09/00
PHE 50 S
Mounting the
complete sleeve 1Fasten the spring (2) with the screws (1).
2Insert the complete sleeve (A) into the
gear housing (B) and take care that the
piston and the sleeve (A) are aligned. If
necessary, align the piston centred
through the gear housing opening.
3Insert the O-ring (C) into the gear housing.
4Mount the housing (6) on the gear hous-
ing (B) and tighten down the five
screws (7) with their washers.
5Insert the O-ring (5), the actuator (4), and
the spring ring (3).
☞The actuator (4) must be mounted
such that it grasps the groove of the
drive sleeve (F).
6Fit the gasket (D) and the cap (E) and fas-
ten it with the 4 nuts (9) (torque = 3 Nm)
and the washers.
7Insert the felt (8).
Mounting the
gear cover
Mounting the
field and the
armature
1Mount the gear cover (6) and fasten it with
two screws (7) to the gear housing (8).
☞The two screws (7) must be covered
with screw locking device.
2Push the armature (5), turning it slightly,
through the gear cover (6) into the gear.
3InserttheO-ring(B)alignedintothemotor
housing (9) and mount the field together
with the motor housing (9). Mind the right
position!
4Fasten the field with the motor housing (9)
to the gear cover with four screws (4).
5Mount the brush holders (3) and fix them
with the screws (A).
6Carefully lift the carbon brush springs on
both sides and insert the carbon brush-
es (2).
Fit the cable lugs (1).
☞Attention: Mind the mounting position
of the flat spiral spring (C): Pre-tension
the spring 3/4 turn!
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Repair Instructions Nr.183.09/00
PHE 50 S
Mounting the
locking elements 1For further assembly, rotate the machine as shown in illustration:
Push the O-ring (1) and the bearing
sleeve (2) over the housing (3).
2Place the disc (5) and the pressure
spring (6) between housing (3) and spin-
dle sleeve (4).
3Place the plate (7) on the pressure
spring (6) and depress the latter. Let the
locking elements (8) engage in the
plate (7) and the spindle sleeve (4).
4Fit the retainer (9), the damper ring (A) as
well as the stop (B) and secure them with
the spring ring (C).
Mounting the
trigger,
Mounting the
handle
☞Place the machine on its side on a
mat (1.), to prevent the plate springs
from falling down!
1Place 2 plate springs (1) and (2) on the
trigger.
☞First fit the spring with the side shap-
ing (2) then fit the spring without the
side shaping (1). If necessary, break
off the side shapings of plate
spring (1).
2Fit the gear housing insulation (5) to the
machine.
Mountthetrigger (4) and secure it with the
screw (3). Mind the right position!
3Fitthesleeve(6) andpushbackandpress
on the end cover cap (7).
4The following parts must be mounted:
clamping ring (A),
screw (9),
plastic cover (8),
support (B),
clamping ring (C).
5Insert the fan type lock washer (F) into the
handle (D), fit the screw (E) and screw
down the handle (D).
6Mount (G) the depth gauge.
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Repair Instructions Nr.183.09/00
PHE 50 S
Mounting the
electric
components and
the Softgrip
1Insert the service LED-module with RTR
chip (2) into the housing and fix it with the
screw (1).
2Lead the connection cable (9) through the
Softgrip (8) and connect the switch (7)
with the RTR chip (2).
3Fix the connection cable (9) with aid of the
cable clamp (5) and the screw (6).
4Hang up the Softgrip (8) at the top of the
handle and press it down.
5Mount the screw (A) to fix the Softgrip (9).
6Fit the cover (3) on both sides and fix it
with the screws (4).
Fastening the
complete handle
and the motor
cover
1Push the complete handle (4) over the
housing and fasten it with the screws (3)
and (5) as well as the distance sleeve (6).
2Fix the motor cover (2) with two
screws (1).
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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