Atlas Copco PHE 3 - User Manual

This document outlines the repair and maintenance procedures for the Atlas Copco PHE 3 and PHE 3X devices, focusing on detailed dismantling and assembly instructions for various components. The device appears to be a power tool, likely a hammer drill, given the references to a hammer mechanism, SDS-Plus reception, and components like a striker and planetary gear.

Function Description

The Atlas Copco PHE 3 and PHE 3X are power tools designed for tasks requiring a hammer mechanism, such as drilling into hard materials. The device incorporates an SDS-Plus reception system, indicating its compatibility with SDS-Plus drill bits, which are commonly used for rotary hammer drills due to their quick-change capability and efficient power transfer. The internal structure includes a motor, a gear housing with planetary gears, a spindle, and a hammer mechanism with a striker and plunger, all working in conjunction to deliver both rotary and percussive action. The electrical components, including a switch, capacitor, and triac, control the motor's operation, while carbon brushes ensure electrical contact with the armature. The device is designed for robust performance, with various bearings and O-rings to ensure smooth operation and sealing against contaminants.

Usage Features

The device is operated via a switch lever, which likely controls different modes of operation (e.g., rotary drilling, hammer drilling). The SDS-Plus reception allows for quick and secure insertion and removal of drill bits, enhancing user efficiency. The handle is designed for user comfort and control, incorporating a silicone buffer for vibration dampening and a handle bolt for secure attachment. The motor cover and service cover provide access to internal components for maintenance while protecting them during operation. The overall design emphasizes durability and ease of service, as evidenced by the detailed repair instructions.

Maintenance Features

The manual provides comprehensive guidance for maintaining the PHE 3 and PHE 3X, ensuring longevity and optimal performance.

General Maintenance:

Regular maintenance is strongly recommended, especially if carbon brushes are cut off or the hammer mechanism fails. When performing maintenance, all parts of the maintenance set must be exchanged. Specific maintenance sets are provided for different voltage versions of the PHE 3 and PHE 3X.

Dismantling and Assembly:

The manual meticulously details the step-by-step process for dismantling and assembling various sections of the device.

• Carbon Brushes: Instructions are provided for removing the service cover, cable, brush holder, spring, and carbon brushes. For assembly, the brush holder is inserted, cables connected, carbon brushes and springs fitted, and the service cover fastened.
• SDS-Plus Reception (PHE 3): Dismantling involves removing the rubber, spacer, depressing the sliding sleeve, levering off the seal ring, removing the sliding sleeve and retaining ring, depressing the retaining disk, pressing out the ball, and removing the retaining disk and spring. Assembly is the reverse, with careful attention to inserting the spring, retaining disk, ball, retaining ring, sliding sleeve, seal ring, spacer, and rubber.
• FIXTEC-Reception (PHE 3X): Dismantling includes removing the locking sleeve using a pulling-off device, depressing the seal ring to remove the balls, and then removing the seal ring, outer spring, ejector ring, inner spring, and washer. Assembly involves pressing in the seal ring, fitting the washer, inner spring, outer spring, locking ring, depressing the locking ring to insert the balls, inserting the ejector ring, and fixing the locking sleeve. A locking ring can be fitted into the spindle to secure the ejector during mounting.
• Gear Housing: Dismantling involves removing the switch lever (which is destroyed in the process), housing screws, and the locking ring (for PHE 3X) using special pliers. Assembly includes fitting the gasket, fastening the gear housing to the motor housing with screws, and fitting the switch lever in the "hammer" position.
• Spindle: Dismantling involves removing two screws, the straight pin, planetary gear, ring gear, and the complete spindle sleeve. Assembly includes fitting the spindle to the motor housing with screws, pushing the ring gear over the back gear shaft, pushing the planetary gear onto the back gear shaft, and pushing the straight pin through the locking slide into the motor housing.
• Striker: The striker is removed by placing the spindle vertically and hitting the plunger with a mandril. For assembly, the striker is greased and inserted into the cylinder.
• Spindle (Outer Parts): Dismantling involves levering off the special locking ring, removing the thrust bearing components (washer, thrust bearing, compensating washers, profile ring with damper-O-ring), removing the retaining clip and locking slide, pressing the spindle wheel with a sleeve to release the locking ring, and removing the ratchet and disk springs. Assembly involves mounting the disk springs, clutch (ratchet), locking ring, locking slide, retaining clip, and the rear thrust bearing components, securing it with the special locking ring.
• Spindle (Inner Locking Ring): Depending on the date of manufacture, different methods are used. For older models (up to 12/95), special pliers are used to remove the locking ring. For newer models (from 09/96) with deairing holes and a service boring, a service tool and screwdriver are used to turn and lever off the locking ring.
• Spindle (Inner Parts - PHE 3): Dismantling involves pressing out the washer, pressure sleeve, plunger, and brake disk, then removing O-rings. Assembly includes pushing O-rings onto the pressure sleeve, fitting the brake disk, O-ring, and pressure sleeve to the plunger, inserting them into the spindle, inserting the washer, and pressing the locking ring with a used cylinder.
• Spindle (Inner Parts - PHE 3X): Dismantling involves pressing out the washer, pressure sleeve, plunger, brake disk, and pressure sleeve, then removing O-rings. Assembly includes inserting O-rings into the pressure sleeves, pressing the pressure sleeve into the spindle, pushing the brake ring and pressure sleeve over the plunger, inserting them into the spindle, inserting the washer, and pressing the locking ring with a used cylinder.
• Back Gear Shaft and Cylinder: Dismantling involves pulling out or loosening the bearing housing, removing the tumble drive and cylinder, pressing out the bolt and removing disks, and removing the needle bearing and rollers. Assembly includes inserting disks and the bolt into the cylinder, inserting rolls into the back gear shaft (with grease, or with a cage for newer models), inserting the back gear, and greasing the striker before inserting it into the cylinder.
• Back Gear Shaft: Dismantling involves removing the O-ring, compensating washer, disk, thrust bearing, and pressing off the back gear wheel, then removing tumble drive, washer, coupling box, spring, and washer. Assembly involves pushing washer, spring, coupling box, washer, and tumble drive onto the back gear shaft, pressing on the gear wheel with a specific distance, greasing and fitting the thrust bearing and disk to the gear wheel, checking the distance "X" for the disk, and inserting the locking ring.
• Angle Drive: Dismantling involves removing the locking ring and the angle drive with washers and support ring. Assembly includes inserting the support ring, greasing and inserting the angle drive, inserting washers (noting that the number of washers should match the number removed), and inserting the locking ring.
• Motor Cover: Dismantling involves loosening screws and removing the motor cover, then removing the rubber cap (which may be glued). Assembly involves fitting the motor cover and fastening it with screws, ensuring the rubber cap is stuck in place (applying glue if necessary).
• Handle: Dismantling involves expelling a pin, removing field supply cables, unscrewing the handle cover, removing the silicone buffer, locking ring, washer, AVS-rubber, handle, and unscrewing the handle bolt. Assembly includes screwing the handle bolt into the housing, pushing the handle over the bolt, fixing the AVS-rubber with washer and locking ring, inserting the silicone buffer, fastening the handle cover with screws, leading field supply cables through channels, and fastening the handle with the bolt.
• Electrical Parts: Dismantling involves unscrewing the strain relief and removing the switch, capacitor, triac, mains cable, and field cable. Assembly involves connecting all cables to the switch according to the wiring diagram, pushing field cables through the handle, inserting the switch, capacitor, and cooling plate with triac into the relief, ensuring cables are fitted properly, and fastening the strain relief with screws.
• Motor: Dismantling involves loosening screws and pulling out the motor (hitting the motor housing lightly if necessary). Assembly involves inserting the motor into the motor housing (ensuring the lug fits into the relief) and fastening it with screws.
• Armature: Dismantling involves removing the seal ring, pushing out the angle, removing the silicone buffer, pulling out the armature, pressing off the toothed wheel, and removing the washer, sealing ring, and bearing. Assembly involves pushing the bearing, washer, and seal ring onto the armature shaft, pressing on the toothed gear, inserting the complete armature into the field, pushing the silicone buffer onto the field housing, fixing the angle, and pushing the seal ring onto the field housing.
• Field: Dismantling involves removing the air deflector plate and silicone buffer, then pulling the field from the field housing and removing centering ledges. Assembly involves fitting centering ledges to the field, inserting the field into the field housing (hitting lightly if necessary), inserting the silicone buffer into the air supply ring, and inserting the air deflector plate.

Lubrication:

At each maintenance, the tool must be lubricated as shown in the lubrication chart, which specifies the type and amount of grease for various components (e.g., spindle wheel toothing, back gear hollow, O-rings, needle bearing, plunger, cylinder inside/outside, striker, tumble drive boring, gear sleeve, ratchet/spindle wheel, angular wheel, thrust bearing). Used grease must be completely removed and replaced with new grease. The service set contains tubes with Darina and Tivela grease, and any remaining Darina grease should be used to evenly lubricate the gear box and spindle sleeve.

Cleaning:

All parts, except electrical components, must be cleaned with cold cleaner. Care must be taken to prevent cleaner from entering encapsulated bearings. Electrical parts should be cleaned with a dry brush.

Abrasion Test:

Dismantled parts should be visually checked for abrasion and exchanged if necessary.

Electrical Test:

Before assembly, all relevant parts must undergo an electrical test as described in the "Electrical and Mechanical Test Instruction" chapter. A final electrical examination is also required after assembly.

Test Run:

After assembly, a test run should be performed to check for strange noises.

Screw Locking:

All screwed connections in metal should be additionally secured with a screw locking device.

This comprehensive maintenance guide ensures that the Atlas Copco PHE 3 and PHE 3X devices can be effectively serviced, prolonging their operational life and maintaining their performance standards.