Atlas Copco PN 6000 S Setup guide

PAGE

Repair Instructions No.178.06/97

PN 6000 S

Special Tools

Required

■

Torx screwdriverTX 15 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

Remove the depth gauge (2) with the

holding device (3) from the tool.

Remove the holding device (3) from the

depth gauge (2).

Remove the holding grip (1).

Remove the locking ring (9) with aid of

special pliers and remove the O-ring (8).

Remove the plastic holder (7) from the

tool.

Remove the pin (4) and the nut (6) from

the clamping plate (5).

Slightly bend up the clamping plate (5)

and push it off.

Detaching the

switch knob

Remove the four screws (6).

Carefully lever off the gear box insula-

tion (3) at the edge using a screwdriver.

Remove the O-ring (5) from the gear box

insulation (3). Remove the locking ring (4)

with aid of special pliers.

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).

Remove the shift pin (7) and the torsion

spring (8) from the gear box insulation (3).

6 5

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Repair Instructions No.178.06/97

PN 6000 S

Removing the

armature

Loosen the four screws (B) and remove

the motor housing cap (A).

Remove the respective brush springs (2)

from the carbon brushes (D) and place

them on the upper edge of the brush

holder (E).

Pull the cable lugs (1) and (C) from the

carbon brushes (D) and pull out the car-

bon brushes.

Slightly lift the brush holder (E), unlatch

them (see arrow) and take them out.

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.

Removethebearingbush(9)fromtheball

bearing (8).

Press the ball bearing (8) as well as the

ball bearing (4) from the armature with aid

of the forcing disks (service tool).

If necessary, press the fan (7) from the ar-

mature (6).

Remove the plug (5) from the armature (6).

Removing the

electric

components

Remove the handle screw (C) steadying

the knurled nut (5) at the same time. Re-

move the knurled nut (5).

Loosen the screw (9) and lever off the soft

grip (8).

Remove the four screws (B) of the handle

shell (A).

Remove the handle shell (6) with the hold-

ing-down device (3).

Loosen the cable clamp (7) and lay bare

the connection cable (E) with the protec-

tion cover (F).

Pull off the switch connection wires (1)

and (2).

Remove the switch (D) with the capacitor

from the handle shell (6).

Remove the sleeves (4) and the handle

shell (A).

Detaching the

field

Remove the motor housing (1) with the

field (2) from the crankcase.

Loosenthetwoscrews(3)andremovethe

field (2) from the motor housing. If neces-

sary, use a plastic hammer for support.

DED

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Repair Instructions No.178.06/97

PN 6000 S

Detaching the

damping element

Loosenthetwoscrews(4)andremovethe

gear box insulation (2) and (3).

Loosen both screws (5) of the handgrip

holder (7) and remove them together with

the disks (6).

Remove the handgrip holder (7) and the

damping element (8).

☞

Attention: Do not dismantle the damp-

ing element (8)!

Remove the rubber collar (1).

Removing the

crankcase top

cover

Lever off the cap (5).

Remove the four screws (6).

Loosen the screw (4) steadying the crank

gear from below with aid of a screwdriver

(see arrow).

Remove the crankcase top cover (3) and

the gasket (7).

Remove the locking ring (2) with aid of

special pliers and push out the ball bear-

ing (1).

6 5

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Repair Instructions No.178.06/97

PN 6000 S

Detaching the

bearing end plate

Lever off the cap (3) with aid of a screw-

driver.

Remove the distance sleeve (4) and the

sleeve (5) from the machine.

Loosen the four screws (F). They are fas-

tened very tightly.

Remove the flange (G).

Remove the distance sleeve (6) and the

sleeve (7).

☞

Remove both locking levers (D) by

depressing the retaining plate (E)

against resilience. Remove the retaining

plate (E).

Remove the pressure spring (C).

Remove the bearing end plate (1) com-

pletely with the spindle sleeve from the

crankcase (8).

Remove the gasket (2).

Remove the locking ring (B) with aid of

special pliers.

Remove the backing flange (A) and the

felt washer (9).

543

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Repair Instructions No.178.06/97

PN 6000 S

Dismantling the

spindle

Press the spindle sleeve (7) with the

spindle gear (G) from the bearing end

plate (A).

Lever off the seal ring (8).

Remove the locking ring (9) with aid of

special pliers.

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).

Remove the four pins (H) with aid of a

magnet.

Remove the spindle sleeve (7) with the

O-ring (6) from the spindle gear (G).

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).

Loosenthetwoscrews(1)andremovethe

cylinder (4) with the percussion body (2)

and the O-ring (3) from the crankcase (5).

PAGE

Repair Instructions No.178.06/97

PN 6000 S

Dismantling the

reduction gear 1Loosen the two screws (K) and pull the in-

dexing sleeve (H) completely from the

crankcase (6).

2Remove the bearing (J) and the indexing

sleeve (H).

3Press down the bevel gear (4) with aid of

the disassembly tool (service tool).

4Keepitdepressedandremovethelocking

ring (5) with aid of special pliers.

5Remove the bevel gear (4), the ball bear-

ings (3 and F), the needle bearings (7

and 2), the coupling (1), the backing

flange (8), the pressure spring (9), the

coupling sleeve (A), the coupling (B), the

balls (C), the indexing sleeve (D) as well

as the pinion (G) 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 aid of

an interior extractor.

5Press the pin (6) from the piston (5) and

remove the piston (5).

6Push the needle bearing (8) from the con-

necting rod (7).

9AB

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Repair Instructions No.178.06/97

PN 6000 S

Maintenance

General It is recommended that maintenance be performed on the machine at regular intervals or when the car-

bon brushes switch off at the latest.

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).

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 2,5 Nm

Screws in metal 4,0 Nm

Gear box screws 15,0 Nm

PAGE

Repair Instructions No.178.06/97

PN 6000 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), the backing

flange (8), the pressure spring (9), the

coupling sleeve (A), the coupling (B), the

balls (C), the indexing sleeve (D) as well

as the pinion (G) 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 indexing sleeve (H) with the

boring facing downward.

4Mount the bearing (J) on the reduction

gear.

5Insert the reduction gear completely

withthe indexing sleeve (H) intothecrank-

case and fasten it with the two secured

screws (K).

9AB

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PAGE

Repair Instructions No.178.06/97

PN 6000 S

Assembling the

spindle 1Insert the cylinder (4) with the percussion

body (2) and the O-ring (3) into the crank-

case(5)and fastenitwiththe foursecured

screws (1).

2Insert the O-ring (N), the snap die (M), the

disk(L),theO-ring(K)andthedisk(J)into

the spindle gear (G). Fit the disk (L) with

the phase facing the snap die. Mind the

right position!

3Push the spindle sleeve (7) with the

O-ring (6) over the spindle gear (G).

4Lock the spindle gear with the four

pins (H) using a magnet for support.

5Mounttheneedlebearing (B), thedisks(C

and E), the cup springs (D) as well as the

needle bearing (F) in the bearing end

plate (A).

6Mount the locking ring (9) with aid of spe-

cial pliers.

7Insertthesealring(8) into the bearingend

plate (A).

8Push 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.

2Mount the locking ring (B) with aid of spe-

cial pliers.

3Fit the gasket (2) and the bearing end

plate (1) completely with the spindle

sleeve to the crankcase (8).

4Push the pressure spring (C) and the re-

taining plate (E) over the spindle sleeve

and depress them.

5☞Press in both locking levers (D) from

the side against resilience.

6Push the distance sleeve (6) and the

sleeve (7) over the spindle sleeve.

7Push the flange (G) over the spindle

sleeve (7) and fasten it tightly with the four

secured screws (F) (15 Nm).

8Push over the distance sleeve (4) and the

sleeve (5).

9Mount the cap (3).

543

9AB

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