Atlas Copco PHE 20 Setup guide

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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Special Tools
Required
■ Allen key
■ (Dis-)assembly set 4931 599011
■ Repair tool set 4931 599016
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
Dismantling the
carbon brushes
1
Loosenthefivescrews(4)andremovethe
upper handle cover (3).
2Remove the cable collar (2).
3Disconnect the power supply lead togeth-
er with the cable entry sleeve (5) from the
switch (1) and remove them.
4Branchoffallthestrandsfromtheswitch(1),
from the capacitor (6) and from the brush
holder (7). Remove the switch (1) and the
capacitor (6).
5Pull the strands from the brush holder (7).
Pull out the brush holder (7) and remove
the carbon brushes (8).
Dismantling the
wheel shaft 1☞Remove all six gear screws. Remove
the gear box completely with the bear-
ing end plate and the armature from
the motor housing.
2Loosen the four screws and remove the
housing cover (1).
3Pull the cylinder (3) together with the per-
cussion body (4) from the motor housing.
Remove the piston con-rod (5) from the
wheel shaft (6) and take it out.
4Remove the four cylinder screws (2) and
completely remove the wheel shaft (6).
5Push the sleeve (8) (special tool) onto the
bearing cover (7). Press off the sun wheel
andtheballbearing.Thebearingcover(7)
gets destroyed.
6Removethe airdeflector plate(9) fromthe
motor housing.
7Beat the field from the motor housing.
☞Take care that the field was discon-
nected beforehand.
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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Dismantling the
gear box
1
Carefullyremovethe bearingendplate (9)
from the gear box (2) (lever it off with aid
of a screwdriver).
2Remove the gasket (3).
3Expel the armature (8) by hitting the bear-
ing end plate (9) lightly with a plastic ham-
mer.
4Remove the two screws (4).
5Put the bearing end plate (9) onto a pad.
Press out the reduction gear shaft (1)
through the sun wheel (7) with aid of a
mandril.
6Place the reduction gear wheel (6) to a
sleeve(repairtoolset; service tool). Press
out the sun wheel (1) with aid of a screw
press.
7Remove the gear wheel (6), the bearing
cover (5) and the bearing.
Dismantling the
snap die 1Remove the intermediate wheel (8) with aid of a plastic hammer and press off the
ball bearings at both sides.
2Completely remove the locking ring, the
set collar (2), the O-ring (1), and the set
collar from the spindle gear.
3Remove the O-ring (3), the disc (7), the
spring sleeve (4), the ball, and the sleeve
(6).
4Remove the rolls (5) and both balls.
5Applicable for the new SDS-Plus-System
(A): the rolls (5) are replaced by balls.
6Press out the snap die (9).
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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Dismantling the
spindle gear
1
Remove the disc (1), as well as the locking
ring, the bearing cover, the disc, the locking
ring, the ball bearing, and the seal ring (2).
2Press the complete spindle (3) from the
gear box.
3Push back the ring (8) and the cup
springs (7) with aid of the disassembly
tool (4)(servicetool)andremovethelocking
ring (9) with aid of special pliers.
4Remove the disassembly tool (4) from the
spindle (3) and remove the locking ring.
5Removethering (8),the cupsprings (7),the
disc (6), the balls, and the spindle gear (5).
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Maintenance
General It is recommended to regularly submit the tool to maintenance, or as soon as the hammer mechanism
gets weak, or when the carbon brushes switch off. When carrying out maintenance all parts of the main-
tenance set must be exchanged. Use the respective maintenance set provided for each machine.
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).

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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
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 grease 10 g Tivela
B Cover with grease 10 g Darina
C Fill with grease Tivela
Torques Gear box screws 3,0 Nm
(additionally secure with screw locking device)
Housing screws (plastic) 2,0 Nm
B
A
A B
BB
B
C
A A
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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Assembly
Pre-assembling
the reduction
gear shaft
1
Pre-assemblethereductiongearshaft(1),
the reduction gear wheel (2), the bearing
cover (3), and the ball bearing (4).
2Press the pre-assembled components
into the bearing end plate (7). Fasten it
with additionally secured screws (Omnifit).
3Measure the center distance of the sun
wheel (6). If necessary, correct the dis-
tance with washers.
☞Set the center distance with aid of the
sleeve (8) (repair tool set; special tool)
to 60,5 - 0,05 mm. Check the distance
between the upper and the lower part
with aid of a feeler gauge and set the
tolerance to - 0,05 mm with washers.
4Press on the sun wheel (6) with aid of the
repair tool set (8) (service tool).
5Fit the complete armature to the bearing
end plate (7). Mind the right position.
6Insert the O-ring (5) into the bearing end
plate (7).
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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Mounting the
spindle gear
1
Push the spindle gear (6) completely with
greased balls (5), disc, cup springs (7),
ring (8), and locking ring onto the spindle.
2Push back the ring (8) as well as the cup
springs (7) with aid of the assembly tool (9)
(servicetool)andmountthelockingringwith
aid of special pliers.
3Insert the complete spindle into the gear
box.
4Mount the seal ring (4), the ball bearing, the
locking ring, the disc (3), bearing cover (2),
the locking ring, as well as the disc (1).
Mounting the set
collar 1Insert the disc (2). Insert the rolls (3) with grease.
2Applicable for the new SDS-Plus-System
(A): the rolls (5) are replaced by balls.
3Slide on the sleeve (4) together with the
ball.
4Mount the spring sleeve (5), the disc, the
O-ring (6), the set collar, the cover (8), the
locking ring, and the O-ring (9).
5Insertthesmallintermediatewheel(7)into
the gear box and fit it together with the
gasket (1) to the bearing end plate.
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Repair Instructions No.163.01/96
PHE 20 / PHE 26 / PHE 200
Mounting the
wheel shaft
1
Completely assemble the wheel shaft (6)
and press the reduction gear flush onto
the wheel shaft.
☞
Use a new bearing cover (7).
2Insert the complete wheel shaft into the
motor housing (8) and fasten it with
screws. Additionally secure the screws
with screw locking device.
3Insert the percussion body (4) and the pis-
ton con-rod (5) together with the four-lip-
seal-ring into the cylinder (3).
4Insert the cylinder (3) into the motor hous-
ing (8) and insert the con-rod into the
wheel shaft tappet.
5Insert the field and the air deflector
plate (9) into the motor housing (8).
6Fasten the pre-assembled bearing end
plate with screws to the gear box. Addi-
tionally secure the screws with Omnifit.
7Fasten the completed gear box to the mo-
tor housing (8) with screws. Additionally
secure the screws with Omnifit.
8Fit the housing cover (1) together with the
gasket and fasten it with screws.
Mounting the
carbon brushes 1Insert the carbon brushes (9) into the brush holders (8) and mount the plug con-
tacts.
2Insert the brush holders (8) with the car-
bon brushes (9) above the armature col-
lector into the reliefs of the lower handle
shell (1). Take care that the strands of the
armature collector keep free.
3Install the switch (2) and the capacitor (7) to-
gether with all the strands into the provided
reliefs of the handle shell (1) and connect
them according to the wiring diagram.
4Mount the power supply lead and the ca-
ble entry sleeve (6) with the cable clip (3).
Connect the power supply lead according
to the wiring diagram.
5Fasten the upper handle shell (4) with the
five screws (5).
Test Run
Electrical Test
Check the direction of rotation!
Let the machine run-in.
Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).
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