Atlas Copco BBS1100 Einrichtungshandbuch

Repair Instructions No.521.09/00

BBS(E)1100

Atlas Copco

Electric Power Tools Ltd.

4939 5240 01

(10/00)

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

Loosen all five screws (4) and remove the

handle cover (1).

Unscrew the strain relief (3).

Removethe connectioncable(2) from the

handle shell.

Detaching the

toothed belt,

Removing the

carbon brushes

Unscrew the blower cover (1).

Remove the air deflector ring (2).

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.

Remove the fan (A).

Loosen four screws (4) and remove the

bearing end plate (5).

Remove the belt guard (8) and lever off/

twist off the toothed belt (7).

Unscrew the two brush holder caps (B)

and remove the carbon brushes (C) on

both sides.

Loosen the screw (D)and remove the tri-

ac (E).

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!

PAGE

Repair Instructions No.521.09/00

BBS(E)1100

Removing the

field and the

armature

Pull out the armature (2) and remove the

air deflector ring (5).

Pressofftwoballbearings(1)and(4)from

the armature (2) with aid of the forcing

discs (service tool).

Remove the seal ring (3).

Loosen both field screws (A) and remove

the spring washers (B). Branch off the

field (6) and remove it.

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.

Loosen both screws (D) and remove the

carbon brush holders (C) on both sides.

Detaching the

spring steel

sheet

Loosen two screws (1).

Remove the spring steel sheet (3) and the

support for the sand belt (4).

Unscrew the four screws (2) through the

openings in the absolute unit.

Remove the absolute unit (5) from the mo-

tor housing.

2 3 4 5 6

21 3 4

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Repair Instructions No.521.09/00

BBS(E)1100

Detaching the

driving roll

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!

Loosen the two screws (5).

Remove the gear box cover (7) and the

gasket (6).

Remove the locking ring (4) with special

pliers.

Remove the driving roll (1) with the

spring (2) and the washer (3).

Detaching the

pinion

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).

Pull the sleeve (6) from the pinion (7).

Press off the ball bearing (8) from the pin-

ion (7).

Remove the ring (9), the disc (5) and the

washer (3).

Extract the bearing sleeves (1) and (2)

with a suitable interior extractor.

Removing the

T-screw

Unscrew the nut (7) with a socket spanner

(SW7). Remove the sealing washer (6).

Unscrew the T-screw (1).

Remove the sealing washer (4), the back-

ing flange (3) and the spring (2). Remove

the ring (5).

Loosen the screw (D) and remove the ten-

sion lever (C) as well as the distance

sleeve (B).

Remove the steering roller (E) with the

spring (A).

☞

The steering roller is under spring

pressure!

Loosen both screws (8) and remove the

cover (9).

2 3 4

6 8

7 9

8 9

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Repair Instructions No.521.09/00

BBS(E)1100

Dismantling the

steering roller

Pull out the steering roller axis (1) and re-

move the spring (9).

Detach the steering roller (6) and the

washers (4) and (8).

Extract the bearing sleeves (5) and (7)

with a suitable interior extractor.

Remove the guide (3) and the spring (2).

4 6 7 8

2 3

PAGE

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

Cover with 5g grease Alvania R2.

Torques

Screws in plastic 1.5 Nm

Screws in metal 2.0 Nm

3 g

A1 g

1 g

PAGE

Repair Instructions No.521.09/00

BBS(E)1100

Assembly

Assembling the

steering roller

Mount the guide (3).

Press the bearing sleeves (5) and (7) into

the steering roller (6).

Insert the steering roller (6) with the wash-

ers (4) and (8) into the steering roller sup-

port (9).

Insert the steering roller axis (1).

Pre-mount the spring (2).

Mounting the

T-screw

Insert the cover (9) and fasten it with two

screws (8).

Mount the spring (A) on the steering roller

support.

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.

4 6 7 8

2 3

8 9

3 54

PAGE

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.

6 7

13 4

23456

PAGE

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).

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