Atlas Copco PH 5 H Setup guide

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
2
Dismantling the
nosecone
3
Dismantling the
nosepiece
(PH 5 H, PH 5 F)
4
1Hit the top housing (4) with a plastic
hammer to loosen the nosepiece (1) and
remove the nosepiece.
2Remove the tolerance ring (2) and the
nosepiece seal (3).
12 3
1Hold the upper part of the machine in a
vice.
2Lever out the nosecone retainer (1) with a
screwdriver and remove it.
3Twist the nosecone (2) such that its four
reliefs match with the reliefs of the
nosepiece retainer (3) which is located
underneath.
4Place the service tool 9170 3212 00 such
that its four lugs grasp the reliefs and
unscrew the nosecone clockwise.
5Remove the O-ring (5) (only PH 5 H,
PH 5 F).
6Remove the the front handle strap
assembly (4) and the nosepiece
retainer (3).
4
123 4
5
☛
The steps 4-7 describe the dismantling of machines with spline shaft reception (PH 5 H, PH 5 F).
For dismantling machines with SDS-max reception (PH 5 S), please proceed with step 8.
Note
Detaching the
front bearing
housing
(PH 5 H, PH 5 F)
12
1Hold the machine in a vice.
2Unscrew and remove the front bearing
housing (2) with service tool 9170 3020 90
(left-handedthread!).
3Remove the driver together with the barrel
(1) from the machine.
Separating the
driver from the
barrel
(PH 5 H, PH 5 F)
12
1Fix the service tool no.9170 3022 60 in a
vice.
2Fix the driver (1) together with the barrel
(2) in the service tool and unscrew the
driver (1) (only PH 5 F) from the barrel (2)
with aid of an Allen key. 1
2
PH 5 H
PH 5 F
PH 5 H
PH 5 F
PH 5 H
PH 5 F
5
6

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
3
Dismantling the
barrel
(PH 5 H, PH 5 F)
Dismantling the
barrel
(PH 5 S)
1Remove the complete barrel (7) from the
housing (if necessary, hit the housing
lightly with a plastic hammer).
2Remove the O-ring(1) and the sleeve (2).
3Remove the O-ring (3) from the sleeve.
Lever off the seal ring (4).
4Remove the circlip (5) and press off the
bearing (6).
5Removing the round wire ring (6):
Put a screwdriver (1) through one of the
four service borings and lever off the
round wire ring (leave the screwdriver in
the boring).Lever off the round wire ring
through the other service borings with a
second screwdriver.
6Remove the catcher support ring (4) and
the O-ring (5).
7Remove the recoil transfer ring(2) and the
buffer housing ring (3).
8Press the anvil (9) from the barrel with aid
of a screwdriver and remove the O-rings
(8) from the anvil.
9Expel the junk ring (7) with a mandril.
123
☛
The steps 8-11 describe the dismantling of machines with SDS-max reception (PH 5 S).
For dismantling machines with pline shaft reception (PH 5 H, PH 5 F), please proceed with step 12.
Note
1234
56 7
23456
78 9
1
PH 5 H
PH 5 F
8
PH 5 S
PHE 5 S
1Remove the catcher support ring (1) from
the barrel (3).
2Remove the catcher 0-ring (2).
3Expel the anvil (9) from the driver (6) (hit
the driver lightly with a mandril).
4Remove both seals (8) as well as the
recoil transfer ring (10) and the buffer
housing ring (1) from the anvil (9).
5Remove the circlip (4) and press the driver
bearing (5) from the driver.
6Fix the driver (6) in a vice with the the
anvil facing upward and expel the jumper
ring (7) with a mandril.
45 6 789 1011
7

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
4
Dismantling the
front bearing
housing
(PH 5 S)
Removing the
switch lever
(change-over
switch hammer
drilling/chiselling
(PH 5 S)
1Expel the pin (2) with a mandril.
2Pull out the switch lever (1).
1Fix the machine between cheeks in a vice.
2Unscrew the front bearing housing (2) with
service tool no.9170 3212 00 (1) (left-
handed thread!) and remove it.
☛If necessary, heat up the top housing
where the front bearing housing is located
with a hot-air blower to soften the screw
locking device.
3Remove the spring(5) and the disc (4).
4Press out the ring (3).
12 345
10
12
Dismantling the
roto-stop
(PH 5 S)
1Remove the following parts from the top
housing by hitting the housing lightly with
a plastic hammer:
- star ring (1)
- star sleeve (2).
2Detach the circlip (6) from the star
sleeve (2) and remove the rings (3), (4)
and (5).
12345
11
6
Removing the
switch 1Unscrew and remove the rear handle soft grip (3).
2Remove the lead from the switch (2).
3Remove the switch from the rear handle
front (1).
12 3
1
2
PH 5 S
PHE 5 S
PH 5 S
PHE 5 S
PH 5 S
PHE 5 S
9

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
5
Dismantling the
rear handle
module 1
2
3
4
1Unscrew the handle cover (6) and remove
it from the motor housing.
2Unscrew and remove the cover plate (4).
3Unscrew and remove the cover plate (4).
4Unscrew and remove the upper handle
shroud (1).
Removing the
carbon brushes 1Unscrew and remove the carbon brush covers (4).
2Lift the retaining springs (1) off the carbon
brushes and put them down on the upper
edge of the brush holders (2).
3Remove the carbon brush cable lugs (3)
and carefully pull out the carbon brushes.
5
6
1
2
3
4
1
3
1
4
Dismantling the
motor assembly 1Unscrew and remove the motor housing(5).
2Remove the baffle (1).
3Pull off and remove the leads (6).
4Remove the field coil (2) (if necessary, tap
it lightly with a plastic hammer), minding
the two field location rubbers (3).
5Unscrew and remove the carbon brush
holders (4) from the motor housing.
1
2
3
4
56
1
5

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
6
Dismantling the
gearbox 1Remove the five screws (6).
2Loosen the gearbox (5) by tapping the
gear housing with a plastic hammer, and
remove it.
3Remove the armature (10) from the
gearbox (if necessary, tap it lightly with a
plastic hammer) and remove the bearing
mounting (13) from the commutator
bearing. Remove the commutator bearing
(12) and the insulation washer (11).
4Remove the armature O-ring (7).
5Pull off the bevel pinion lower bearing (4)
and the crankshaft bearing (3) with aid of
an interior extractor.
6Remove the two dowel pins (1) and the
gearbox gasket (2).
1
2
3
4
5
6
7
8
9
10
12
11
13
1
6
Dismantling the
crankshaft 1Unscrew and remove the cover (1).
2Remove the circlip (8).
3Lever off the crank gear (7) with a
screwdriver.
☛To remove the toothed wheel use a
standard extractor size 2.The jaws of the
extractor must be made to fit.
4Remove the crank gear key (3) from the
crankshaft (2).
5Remove the circlip (6) and pull out the
crankshaft.Ifnecessary,pressitoutthrough
the top opening with a suitable mandril.
6Press the crank bearing (5) from the
crankshaft.
7Remove the O-ring (4) from the housing.
17
1
2
3
4
5
6
7
8

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
7
Detaching the
piston and the
connecting rod 345
1Pull the piston (3) from the top housing.
2Pull the striker (1) from the piston and
remove the striker seal(2) from the striker.
3Push the gudgeon pin (4) from the piston
(3) and pull out the con rod (5).
4Press the bearing (6) from the con rod (5).
6
18
Dismantling the
bevel pinion 1Bend down the lugs of the locking plate (8).
2Block the drive gear (6) with a screwdriver
and remove the spring carrier (10).
3Remove the disk spring (9), locking plate
(8), drive gear (6), friction disk assembly
(7), and the distance sleeve (5).
4Remove the circlip (4).
5Pull out the bevel pinion (1) with the bevel
pinion bearing (3):Fix the bearing in a vice
between cheeks and hit the housing lightly
with a plastic hammer.
6Press the bearing (3) from the bevel
pinion (1).
7Remove the O-ring (2) from the motor
housing.
19
Dismantling the
bevel sleeve
(PH 5 S) 123
1Remove the bevel sleeve (1) from the
housing by hitting the front part of the
housing lightly with a plastic hammer.
2Remove the circlip (5).
3Remove the corrugated washer (4).
4Remove the bevel crown wheel(2) with
the bearing (3).
5Remve the bearing (3) from the bevel
crown wheel (2).
4 5
20
1
2
3
4
5
6
7
8
9
10
Removing the
bevel crown
wheel
(PH 5 H, PH 5 F)
12
1Expel the bevel crown wheel (1) from the
top housing with a mandril:lead the
mandril through the top opening of the
housing.
2Remove the crown wheel bearing (2) with
aid of an extractor.
21
PH 5 H
PH 5 F
The tool is now completely dismantled. Further dismantling is not possible.
PH 5 S
PHE 5 S
12

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
8
With the exception of the electrical parts all parts must be cleaned with cold cleaner. Attention! No
cleaner must enter the encapsulated bearings. Clean the electrical parts with a dry brush.
At each maintenance the tool must be lubricated as shown in the lubrication chart. After having
dismantled the entire tool remove the used grease completely and replace by new grease. For
assembly a total of 350 g of grease is necessary. Please pay attention to the following lubrication chart:
It is recommended to submit the tool to maintenance after every 150 work hours, if the hammer
mechanism gets weak, or if the carbon brushes switch off.“When carrying out maintenance all parts of
the maintenance set 9170 3180 30 must be exchanged.
Maintenance
Lubrication
General
Check the dismantled parts for abrasion (visual check) and exchange if necessary.
Before assembly submit all relevant parts to an electrical examination (see chapter Electrical and
MechanicalTest Instruction).
Electrical test
Abrasion test
Cleaning
PH 5 S
PH 5 H
PH 5 F
AAAAAA
B
Legende:
AGenerously cover
BFill
CApply a small quantity
Housing screws............................... 3 Nm
Safety clutch nut.............................. 3 Nm (use Loctite 222 or Omnifit 80 for securing the nuts)
Torque

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
9
Assembly☛When assembling, secure all screwed connections in metal with screw locking deviceNote
Assembling the
bevel crown
wheel
(PH 5 H, PH 5 F)
23
1Press the crown wheel bearing (3) ino the
bevel crown wheel (2).
2Press the crown wheel with the bearing
into the top housing with aid of a suitable
mandril (1).
PH 5 S
PH 5 H
PH 5 F
1
Assembling the
bevel sleeve
(PH 5 S)
1Press the bearing(3) onto the bevel crown
wheel (2).
2Push the crown wheel (2) with the bearing
(3) over the bevel sleeve.
3Fit the corrugated washer (4).
4Mount the circlip (5).
5Insert the bevel sleeve assembly into the
housing as far as it will go.
2
1
123 45
Assembling the
bevel pinion 1Insert the O-ring (2) into the housing.
2Press the bearing (3) onto the bevel
pinion (1).
3Press the bevel pinion (1) together with
the bearing (3) into the housing.
4Insert the circlip (4).
5Push the following parts over the bevel
pinion:
- distance sleeve (5)
- drive gear (6)
- friction disc assembly (7) (the coating
must face the drive gear)
- securing ring (8)
- disk spring (9) (the bulging must face
the spring carrier (10))
6Block the bevel pinion to secure against
twisting and fasten the spring carrier using
a torque wrench with a 32 mm socket as
described below:“Apply the torque wrench
to the spring carrier with enough pressure
to overcome the disk spring resistance,
and secure the spring carrier
☛Torque 3 Nm, use locking device.
7Bend the three lugs of the locking plate (8)
to secure the spring carrier.
1
2
3
4
5
6
7
8
9
10
3

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
10
Assembling the
piston and the
connecting rod
1Press the bearing (6) into the connecting
rod (5).
2Fit the O-ring (2) to the striker (1) and
push the striker into the piston(3).
3Assemble the piston (3) with the
con rod (5) and push the gudgeon
pin (4) through the borings.
Assembling the
crankshaft 1Press the bevel pinion bearing (7) onto the crankshaft.
2Insert the piston with the con rod (3) into
the housing.Insert the crankshaft (4) into
the housing and fit it to the con rod
bearing.
3Fit the circlip (8).
4Fit the crank gear key (5) to the crankshaft
(4).
5Mount the O-ring (6).
6Fit the crank gear (9) with the collar facing
the crankshaft and press it on:steady the
crankshaft (4) with a suitable mandril
which is pushed through the opening in
the housing (otherwise the crankshaft is
pushed in too far).
7Secure the crank gear (9) with the circlip
(10).
8Fill the top housing through the top
opening with approx.25% grease and fit
the con rod access cover (1).
1
4
5
6
7
8
9
10
3
4
5
456
12 3
2
Assembling the
roto-stop
(PH 5 S)
1Fit the rings (3), (4) and (5) to the star
sleeve and secure them with the
circlip (6).
2Push the star sleeve (2) over the bevel
sleeve (7) in the housing.
3Fit the star ring (1) to the star sleeve in the
housing (mind the right position) and push
them in with aid of a mandril as far as they
will go.
PH 5 S
6
1234567

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
11
1Insert the barrel (9) into the front bearing
housing (8).
2Insert the ring (7), the disc (6) and the
spring (5) from the other side into the front
bearing housing (8).
3Apply screw locking device to the thread in
the housing and screw the front bearing
housing together with the previously
inserted parts down to the housing (anti-
clockwise).
☛Take care that the spring(5) is placed
properly to the front bearing housing
(centered, see detailed illustration).
Slightly turn the barrel when screwing
down the front bearing housing, until it
engages in the bevel sleeve.
4Fasten the front bearing housing
(8) with service tool no.
9170 3212 00 (10)
(left-handedthread!)
5Insert the seal ring (4)
into the sleeve (2)
and fit the
O-ring (3).
6Push the
sleeve (2) and
the disc (1)
over the barrel
and simultaneously
insert them into the
front bearing housing (8).
Mounting the
switch lever
(change-over
switch hammer
drilling/
chiselling)
(PH 5 S)
1Insert the switch lever (1).
2Beat in the pin (2) with a mandril.
☛Take care that the pin of the switch
grasps the provided groove of the star
wheel.
12
PH 5 S
9
Assembling the
barrel
(PH 5 S)
23 456
910 11
PH 5 S
1Carefully insert the junk ring (1) into the
barrel (11) with aid of a mandril.
2Fit the anvil seals (2) to the anvil (3) and
insert the anvil into the barrel.
3Insert the following parts into the barrel:
- recoil transfer ring (4)
- buffer housing ring (5)
- catcher support ring (6)
- catcher O-ring (7)
- round wire ring (8) (take care that it
engages is the groove).
4Push the bearing(10) over the barrel (11)
and secure it with the circlip (9).
1
7
78
Assembling the
front bearing
housing with the
bevel sleeve
(PH 5 S) 12 34
PH 5 S
8
10
9
8
765
7

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
12
Refitting the
front bearing
housing
(PH 5 H, PH 5 F)
12
1Hold the machine in a vice.
2Insert the driver (1) with the barrel into the
front bearing housing (2).
3Screw down the front bearing housing (2)
with service tool no.9170 3212 00 (left-
handed thread!) (3 Nm, use screw locking
device).
Refitting the
driver and the
barrel
(PH 5 H, PH 5 F)
12
1Grease the barrel (2) and fasten it to the
driver (1) with screws.
2Hold the service tool 9170 3022 60 in a
vice.
3Insert the barrel and the driver into the
service tool and fasten them with an Allen
key (only PH 5 F) (3 Nm).
12
11
1
2
PH 5 H
PH 5 F
PH 5 H
PH 5 F
1Insert the junk ring (7) into the driver.
2Press the driver bearing (5) onto the driver
and secure it with the circlip (4).
3Grease the anvil (9) and fit two new anvil
seals (8).
☛Take care that the anvil seals are not
twisted.
4Fit the recoil transfer ring (10) and the
buffer housing ring (11) to the anvil (9).
5Insert the anvil (9) into the driver (6).
6Insert a new O-ring (2) into the catcher
support ring (1) and fit the support ring to
the barrel (3).
Assembling the
barrel
(PH 5 H, PH 5 F) 123
PH 5 H
PH 5 F
45 6 789 1011
10
Assembling the
nosepiece
(PH 5 H, PH 5 F)
1Insert the tolerance ring (3) and the
nosepiece seal (4).
2Insert the nosepiece (1) with a plastic
hammer into the top housing (5).
☛The collar (2) of the nosepiece must
be flush with the front bearing
housing(5).
1345
PH 5 H
PH 5 F
13
2

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
13
Assembling the
nosecone 12 3
1Insert the O-ring (5) (only PH 5 H, PH 5
F).
2Insert the nosepiece retainer (3) into the
nosecone (2).
3Insert the front handle strap assembly (4)
such that the lugs of the strap assembly
reach through the opening of the
nosecone (2).
4Place the nosecone (2) on the machine
and twist it such that its four reliefs match
with the reliefs of the nosepiece retainer
(3).
5Place the service tool 9170 3212 00 on
the nosecone such that the four lugs of
the service tool grasp the reliefs of the
nosecone (2).Secure counter-clockwise.
6Fit and secure the nosecone retainer (1).
4 5
14
Assembling the
gearbox 1Press the bevel pinion lower bearing (4) and the bearing (3) into the gearbox (5).
2Insert the two dowel pins (1) and fit the
gearbox gasket (2).
3Fasten the gearbox (5) with five
screws (6).
☛The rear two screws are longer than the
front screws.
4Insert the armature O-ring (7).
5Fit the insulation washer (11) and the
commutator bearing (12) to the armature.
6Fit the bearing mounting (13) to the
commutator bearing (12) and insert the
armature (10) into the gearbox.
15
1
2
3
4
5
6
7
8
9
10
12
11
13
Refitting the
carbon brush
holders
1Insert the carbon brush holders (2) into
the motor housing (3) and screw down
loosely.
2Insert the adjusting tool (4) 9170 0232 60
from the outside through the carbon brush
holders and adjust the carbon brush
holders.
3Secure the carbon brush holders and
remove the adjusting tool.
4Insert the two field location rubbers (1).
16

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
14
Refitting the
motor assembly 1Fit the leads to the field (3).
2Insert the field (with the edges of the leads
facing downward) into the motor housing
(4) and pull the edges of the leads through
the lower housing opening.
3Lead the leads along the outer wall of the
motor housing towards the top and insert
them into the contacts.
4Inser the leads into the fixings.
5Fit the baffle (2) above the field in the
motor housing.
6Fasten the motor housing (4) to the
gearbox (1) with screws.
1
2
3
4
17
Assembling the
rear handle
module 1
2
3
4
1Fit and fasten the upper handle
shroud (1).
2Insert the support rubbers (2 and 3) and
the rear handle front.
3Fit and fasten the cover plate (4).
4Fit the handle cover (6) to the motor
housing and take care that the electrical
contacts on the inner side engage
correctly in the contacts of the motor
housing.
5Fit and fasten the handle cover with
screws. 5
6
Refitting the
carbon brushes 1Place the cable lugs of the carbon brushes (3) on the field using tweezers or
thin nose pliers.
2Insert the carbon brushes into the carbon
brush holders (2).
3Pull the brush holder retaining springs (1)
upwards and push them onto the carbon
brushes.
4Fasten the two carbon brush covers (4)
with screws.
1
2
3
4
18
19

Repair instruction No. 170.6/96
PH 5 H, PH 5 F, PH 5 S, PHE 5 S PAGE
15
Fitting the switch 1 Insert the switch (2) into the
rear handle front (1).
2 Fasten the leads to the switch (2).
3Fasten the rear handle soft
grip (4) with
screws.
12 3
20
1Fit the spring (9) and the retension
disc (8).
2Depress the retension disc (8) against
resilience and insert the locking levers(7).
3Fit the sleeve (6), the rubber ring (5) and
the disc (4).
4Mount the circlip (3).
5Fit the plastic sleeve (2).
6Fit the rubber cap (1).
1Insert the latch bar (4) into the nosepiece.
2Insert the latch spring cover (3) and the
spring (2).
3Insert the latch retainer (1) by hitting it
lightly with a hammer until it sits flush with
the nosepiece.
Refitting the tool
locking
mechanism
(PH 5 H, PH 5 F)
Assembling the
tool locking
mechanism
(PH 5 S)
1
2
3
4
1Fasten the depth gauge locking ring (2)
and the front handle strap guide (4) with
screws (left-handed thread).
2Press together the strap lugs and fix the
strap guide (4) and the depth gauge
locking ring (2) on top.
3Fix the front handle (5).
4Insert the depth gauge (3) and fasten the
front handle.
Assembling the
front handle
1
2
3
4
PH 5 H
PH 5 F
PH 5 S
2
1
34 5 6 789
21
22
Carry out a test run and check for strange noises.
Carry out an electrical test (see chapter Electrical and Mechanical Test Instruction).
Test run and
electrical
examination