Atlas Copco BBS1100 Setup guide

Repair Instructions No.521.09/00
BBS(E)1100
BBS(E)1100
Atlas Copco
Electric Power Tools Ltd.
4939 5240 01
(10/00)

1
PAGE
Repair Instructions No.521.09/00
BBS(E)1100
Special Tools
Require
■ Forcing discs 4931 5990 18
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
handle cover
1 Loosen all five screws (4) and remove the
handle cover (1).
2
Unscrew the strain relief (3).
3
Removethe connectioncable(2) from the
handle shell.
Detaching the
toothed belt,
Removing the
carbon brushes
1 Unscrew the blower cover (1).
2
Remove the air deflector ring (2).
3
Unscrew the centric screw (3) of the
fan (A) and remove the sealing wash-
er (9).
☞
Atthe same time,steady the fan(A) for
support.
4
Remove the fan (A).
5
Loosen four screws (4) and remove the
bearing end plate (5).
6
Remove the belt guard (8) and lever off/
twist off the toothed belt (7).
7
Unscrew the two brush holder caps (B)
and remove the carbon brushes (C) on
both sides.
8
Loosen the screw (D)and remove the tri-
ac (E).
9
Unscrew the pulley (6) with aid of a pipe
wrench (put a piece of cloth in between).
At the same time, carefully steady the ar-
mature, or remove the armature from the
machine.
☞
The pulley has a left-handed thread!
4
12
3
1
1
8
3
5
A
2
9
7
6
CB
4
DE
2

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Repair Instructions No.521.09/00
BBS(E)1100
Removing the
field and the
armature
1
Pull out the armature (2) and remove the
air deflector ring (5).
2
Pressofftwoballbearings(1)and(4)from
the armature (2) with aid of the forcing
discs (service tool).
3
Remove the seal ring (3).
4
Loosen both field screws (A) and remove
the spring washers (B). Branch off the
field (6) and remove it.
5
The switch (8) and the capacitor (9) can
now be removed from the housing shell.
Only applicable for BBSE 1100:
Remove the electronic element with
torque setting wheel (7) from the housing
shell.
6
Loosen both screws (D) and remove the
carbon brush holders (C) on both sides.
Detaching the
spring steel
sheet
1
Loosen two screws (1).
2
Remove the spring steel sheet (3) and the
support for the sand belt (4).
3
Unscrew the four screws (2) through the
openings in the absolute unit.
4 Remove the absolute unit (5) from the mo-
tor housing.
2 3 4 5 6
7
8
9
C
A
B
1
D
3
21 3 4
5
4

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Repair Instructions No.521.09/00
BBS(E)1100
Detaching the
driving roll
1
Remove the pulley (8) with a spanner
wrench. Steady the driving roll (1) with an-
other wrench.
☞
The pulley (8) has a right handed
thread!
2 Loosen the two screws (5).
Remove the gear box cover (7) and the
gasket (6).
3
Remove the locking ring (4) with special
pliers.
4
Remove the driving roll (1) with the
spring (2) and the washer (3).
Detaching the
pinion
1
Expel the pinion (7) with ball bearing (8)
and sleeve (6) by hitting the edge of the
housinglightlywithaplastichammer.This
will also bring out the gear (4).
2
Pull the sleeve (6) from the pinion (7).
3
Press off the ball bearing (8) from the pin-
ion (7).
4
Remove the ring (9), the disc (5) and the
washer (3).
5
Extract the bearing sleeves (1) and (2)
with a suitable interior extractor.
Removing the
T-screw
1
Unscrew the nut (7) with a socket spanner
(SW7). Remove the sealing washer (6).
2
Unscrew the T-screw (1).
3
Remove the sealing washer (4), the back-
ing flange (3) and the spring (2). Remove
the ring (5).
4
Loosen the screw (D) and remove the ten-
sion lever (C) as well as the distance
sleeve (B).
5
Remove the steering roller (E) with the
spring (A).
☞
The steering roller is under spring
pressure!
6 Loosen both screws (8) and remove the
cover (9).
8
1
7
6
54
32
5
1
2 3 4
6 8
5
7 9
6
7
6
5
4
1
2
3
8 9
D
C
B
A
E
7

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Repair Instructions No.521.09/00
BBS(E)1100
Dismantling the
steering roller
1
Pull out the steering roller axis (1) and re-
move the spring (9).
2
Detach the steering roller (6) and the
washers (4) and (8).
3 Extract the bearing sleeves (5) and (7)
with a suitable interior extractor.
4
Remove the guide (3) and the spring (2).
1
9
4 6 7 8 5
2 3
8

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Repair Instructions No.521.09/00
BBS(E)1100
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.
Legend
A
Cover with 5g grease Alvania R2.
Torques Screws in plastic 1.5 Nm
Screws in metal 2.0 Nm
A
3 g
A
A1 g
1 g
A

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Repair Instructions No.521.09/00
BBS(E)1100
Assembly
Assembling the
steering roller
1
Mount the guide (3).
2 Press the bearing sleeves (5) and (7) into
the steering roller (6).
3
Insert the steering roller (6) with the wash-
ers (4) and (8) into the steering roller sup-
port (9).
4
Insert the steering roller axis (1).
5
Pre-mount the spring (2).
Mounting the
T-screw
1
Insert the cover (9) and fasten it with two
screws (8).
2
Mount the spring (A) on the steering roller
support.
3
Insert the T-screw (1) with the spring (2),
the backing flange (3), and the sealing
washer (4) into the absolute unit.
4Insert the completely assembled steering
roller (E) into the absolute unit, and insert
the sealing washer (6).
Push back the steering roller (e.g. on the
edge of a table) and secure the
T-screw (1)withthenut(7),usingasocket
spanner (SW7).
Insert the ring (5).
5Insert the distance sleeve (B) and the ten-
sion lever (C) and secure them with the
screw (D).
Mounting the
pinion 1Mount the bearing sleeves (1) and (2) in the absolute unit.
2Press the ball bearing (5) onto the pin-
ion (4) and mount the sleeve (3).
3Insert the completely assembled pin-
ion (4) into the absolute unit. If necessary,
press it in.
1
4 6 7 8 5
2 3
9
1
7
6
5
4
1
2
3
8 9
D
C
B
A
E
2
1
2
3 54
3

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Repair Instructions No.521.09/00
BBS(E)1100
Mounting the
driving roll 1Insertthedrivingroll (1) with the spring (2) and the washer (3).
Fit the washer (4), the gear (5), and the disc (6)
and secure them with the locking ring (7).
☞After mounting the driving roll (1), fill
the gear area with grease according to
the lubrication chart.
2Fit the gasket (8) and the gear box cover (9)
and fasten them with the screw (A).
3Screw down the pulley (B), steadying the
driving roll (1) with a spanner wrench.
☞The pulley (B) has a right handed
thread!
Mounting the
spring steel
sheet
1Fasten the complete absolute unit (5) to
the motor housing (6) with the four
screws (2).
2Fitthesupportforthesand belt (4) andthe
springsteel sheet (3) andfastenthemwith
the two screws (1).
Mounting the
field and the
armature
1Insert the carbon brush holders (C) and
fasten them with the two screws (D).
2Insert the switch (8) and the capacitor (9)
into the handle.
Only applicable for BBSE 1100: Insert
the electronic element with the torque set-
ting wheel (7) into the housing shell.
3Insertthefield(6)andconnectitaccording
to the wiring diagram, and connect the
electric elements according to the wiring
diagram.
4Fasten the field (6) with two field
screws (A) and the spring washers (B).
5Put the seal ring (3) on the armature (2).
6Press the ball bearings (1) and (4) onto
the armature (2).
7Insert the air deflector ring (5) and the
completely assembled armature (2) into
the housing.
B
1
9
8
54
3
2
6 7
A
4
2
13 4
5
6
5
23456
7
8
9
C
A
B
D
1
6

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Repair Instructions No.521.09/00
BBS(E)1100
Mounting the
toothed belt,
Mounting the
carbon brushes,
1Screw down the pulley (6) and tighten it
manually (not too tight).
☞The pulley has a left handed thread!
2Insert the carbon brushes (C) and screw
down both brush holder caps (B).
3Mount the toothed belt (7).
☞Mount the toothed belt slantwise.
4Fit the belt guard (8) and fasten it with
screws.
5Fasten the bearing end plate (5) with four
screws (4).
6Fit the fan (A) and the sealing washer (9)
and fasten them with the centric screw (3).
☞Steady the fan (A) for support.
7Insert the air deflector ring (2).
8Mount the blower cover (1) and fasten it
with screws.
Mounting the
handle cover 1Mount the connection cable (2) and the strain relief (3).
2Fit the handle cover (1) and fasten it with
the five screws (4).
☞Take care that no connection cables
are squeezed or jammed.
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
3
5
A
2
9
7
6
CB
4
DE
7
4
12
3
8