overhaul instructions - - your #1 ... · pdf fileatlas copco has a strong global sales and...

© 2007 Atlas Copco Construction Tools AB | No. 9800 0800 01 | 2007-10-01

140PS 150PE 180PS 190PE 220PS 230PE 270PS 280PETEXOverhaul instructionsPneumatic breakers

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ContentsTEX 140PS 150PE 180PS 190PE 220PS 230PE 270PS 280PE


ContentsSAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Disposal, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

MACHINE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

TOOLS AND MEDIA/CONSUMABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Standard tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Media / Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Checking the function of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Function of the piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Function of the main valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Function of the tool retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Measuring the tool chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Tool retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Tool chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Tool chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Tool retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Testing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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TEX 140PS 150PE 180PS 190PE 220PS 230PE 270PS 280PE


Overhaul instructions

IntroductionThank you for choosing a product from Atlas Copco. Since 1873, we have been committed to finding new and better ways of fulfilling our customers' needs. Through the years, we have developed innovative and ergonomic product designs that have helped customers improve and rationalize their daily work.

Atlas Copco has a strong global sales and service network, consisting of customer centers and distributors worldwide. Our experts are highly trained professionals with extensive product knowledge and application experience. In all corners of the world, we can offer product support and expertise to ensure that our customers can work at maximum efficiency at all times.

For more information please visit: www.atlascopco.com

About the Overhaul InstructionsThe aim of the instructions is to provide you with knowledge of how to perform a complete overhaul of the pneumatic breaker in an efficient, safe way.

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SAFETY INSTRUCTIONSTo reduce risk of serious injury or death to yourself or others, read these safety instructions before operating or servicing the machine. Post these safety instructions at work locations, provide copies to employees, and make sure that everyone reads the safety instructions before operating or servicing the machine. Comply with all safety regulations.

Safety symbols usedThe indications Danger, Warning and Cautionhave the following meanings:

Danger Immediate hazard which WILL result in serious or fatal injury if the warning is not observed.

Warning Hazard or hazardous procedure which COULDresult in serious or fatal injury if the warning is not observed.

Caution Hazard or hazardous procedure which COULDresult in injury or damage to equipment if the warning is not observed.

Personal precautions and qualifications

Personal protective equipmentAlways use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum:

Protective helmet

Hearing protection

Impact resistant eye protection with side protection

Respiratory protection when appropriate

Protective gloves

Protective boots

Drugs, alcohol or medicationDrugs, alcohol or medication may impair your judgment and powers of concentration.

WARNING Poor reactions and incorrect assessments can lead to severe accidents or death.

Never use the machine when you are tired or under the influence of drugs, alcohol or medication.Prevent other people from using the machine if they are under the influence of drugs, alcohol or medication.

Maintenance, precautionsUse only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability.

Disposal, precautionsA used machine must be treated and disposed of in such a way that the greatest possible portion of the material can be recycled and any negative influence on the environment is kept as low as possible.

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Machine overview

Main partsFor a complete overview of all parts see the Spare parts list.

B

C

D

E

F

G

H

I

J

A K

LM

N

O

P

Q

Trigger

Handle

Spring (for vibration absorbing handle)

Inlet valve

Swivel nut

Swivel

Silencer

Oil plug

Dosing feeder

Tool retainer

Cover

A.

B.

C.

D.

E.

F.

G.

H.

I.

J.

K.

Valve housing

Main valve

Cylinder

Piston

Intermediate part

Tool chuck

Design and functionTEX PS/PE is a range of hand-held, pneumatic breakers designed for medium to heavy demolition of materials such as concrete, asphalt and brickwork. The pneumatic breakers are designed for vertical use. No other use is permitted.

Tools and media/consumable

Standard tools

Tool DimensionMandrel 4 mmMandrel 15.8 mmAllen key 8 mmSocket 10 mmSocket 14 mmSocket 24 mmTorque wrench 47–200 NmOpen heavy duty spanner 41 mm

Special toolsTool Ordering No.Mandrel 3310 1543 00Screw M8 -Wood screw -Gauge, Hex 25 3310 1509 25Gauge, Hex 28 3310 1509 28Gauge, Hex 32 3310 1509 32

Media / ConsumableMachine oil

Loctite® 243™. (Loctite 243 are registered trademarks of Henkel KGaA, its subsidiaries, affiliates, or licensors.

L.

M.

N.

O.

P.

Q.

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OverhaulAfter each operating period of approximately 150 impact hours or twice a year the machine must be dismantled and all parts be cleaned and checked. This work must be performed by authorised staff, trained for this task.

CleaningBefore disassembly, properly clean the outside of the machine.

Checking the function of the machineThrough out the disassembly of the machine the following tests shall be carried out to ensure that the machine is functioning correctly after re-assembly:

Function of the piston

Function of the main valve

Function of the tool retainer

Measuring the tool chuck

Function of the piston

ok

Drop the piston into the cylinder. If there is a contact sound between the piston and the intermediate part, then replace the intermediate part and proceed to point 2. If there is no sound, then proceed with the disassembly procedure.

Drop the piston into the cylinder again. If there is still a contact sound, then replace the piston.

Repeat the test. If there is still a sound, then replace the cylinder.

Function of the main valveWhen the valve is completely re-assembled using a new O-ring, the main valve, the valve cover and the spring pin, shake it up and down and listen for the “click”-sound of the main valve. If there is no sound the valve will not function properly.

Function of the tool retainerOpen the tool retainer.

Insert the insertion tool.

Lock the tool retainer.

Pull the inserted tool strongly outwards.

If the tool comes out, then replace the tool retainer.

Measuring the tool chuck

B A

Too big a clearance between the insertion tool’s shank and the tool chuck will generate increased vibrations. To avoid exposure to excessive vibrations, check the tool chuck for wear every day. Use the gauge that corresponds to the insertion tool’s shank dimension. If it is possible to push the gauge (point A) fully into the tool chuck (to point B) then replace the tool chuck.

1.

2.

3.

1.

2.

3.

4.

8




Disassembly

Silencer1

Cover1

2

Handles1

2

3

4

9




5

6

7

Valve1

2

3

10




4

5

Lubricator1

2

3

Air inlet1

11




2

Tool retainer1

2

3

Piston1

12




Checking the function of the piston

ok

Drop the piston into the cylinder. If there is a contact sound between the piston and the intermediate part, then replace the intermediate part and proceed to point 2. If there is no sound, then proceed with the disassembly procedure.

Drop the piston into the cylinder again. If there is still a contact sound, then replace the piston.

Repeat the test. If there is still a sound, then replace the cylinder.

1.

2.

3.

Intermediate part1

2

13




Tool chuck1

30tons

2

A

The lock wire (A) will be sheared off in two halves. Clear the inside of the cylinder from the remaining half of the lock wire.

AssemblyBefore re-assembly do the following:

Properly clean all parts of the machine.

Oil all parts of the machine.

Replace all O-rings.

Replace all worn or damaged parts.

Tool chuckRotation of tool chuck

ISOpoint to flat

USflat to flat

14




1

5tons

2

Intermediate part1

Put grease on the inside of the intermediate part and slide it onto the piston.

2

15




Piston1

Tool retainer1

2

3

Insert the spring pin with the opening pointing in a 45° angle downwards and outwards.

Air inlet1

16




2

Use Loctite® 243™.

Lubricator1

If the dosing feeder was removed during disassembly, then scrap the old dosing feeder and replace it with a new one.

Valve1

2

3

Tightening torque, 200 Nm.

17




Handles1

2

3

A

B

Screw the guide shaft (A) onto the mandrel (B) (3310 1543 00).

4

5

6

Tightening torque, 47 Nm.

Cover1

18




2

Silencer1

Testing the machineFor testing see the operating chapter in the Safety and operating instructions.

StorageMake sure that the machine is properly cleaned before storage.

Always store the machine in a dry place.

Pour approx. 5 cl of oil directly into the air inlet nipple, connect the machine to the compressed air supply and start it for a few seconds.

DisposalA used machine must be treated and disposed of in such a way that the greatest possible portion of the material can be recycled and any negative influence on the environment is kept as low as possible.

www.atlascopco.com

© 2

007

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Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

overhaul instructions - - your #1 ... · pdf fileatlas copco has a strong global sales and...

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