Repair Instructions No.176.

11/96 PAGE

PB 6S 1
Special Tools ■ Adjustment tool for carbon brushes 9170 3022 60
Required ■ Pulling-off device 9170 0314 440

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
Removing the 1 Unscrew the nut (2) and remove the wash-
auxiliary handle er (3). 3 4
2 Pull out the screw (6).
3 2
☞ Press the clamping ring (1) and re-
move the auxiliary handle (4). Release 5

1
the tension and remove the clamping
ring (1). 6
4 Push back the rubber sleeve (A) and lever 1
off the rubber bushing (5).
5 Remove the rubber sleeve (A).
6 Remove the locking ring (9) with aid of cut
special pliers. If necessary, use a screw-
driver for support.
7 Remove the damping element (8) and the
damper (7). A 9 8 7

Disassembling 1 Remove the locking sleeve (1).

the ball holding
device
2 Depress the retaining plate (2) against re-
silience - the locking levers (3) are re- 1 2 3

2
leased. Remove the locking levers (3).
3 Release the retaining plate (2) and re-
move the pressure spring (6).
4 Remove the locking bolt (4) together with
the ball holding device (5).
6 5 4
5 Remove the ball holding device (5) from
the locking bolt (4). 3

Disassembling 1 Remove all four balls (1) with aid of a mag-

the tool net. 5 6
acceptance
2 Loosen the five screws (B) of the adapter
sleeve (2) and remove the adapter 1 2 3 4
sleeve (2) as well as the O-ring (3). If nec-

3
essary, hit it lightly with a plastic hammer.
3 Remove the tool acceptance (4) com-
pletely with the snap die (A), the
spacer (5) and the gasket (6).
4 Remove the snap die (A) from the tool ac-
ceptance (4).
9 8 7
5 Remove the O-ring (9), the spacer (8), as
well as the recoil ring (7). B A
 Repair Instructions No.176.11/96 PAGE

PB 6S 2
Disassembling 1 Remove the rubber ring (1) and the
the flange sleeve (2).
5
2 Disassemble the flange (3) as described
below: 4
Fasten two hardened screws (4) in the 6 7
flange (3). 4
Fasten the machine in a vice.

☞ Do not fasten the machine too tightly

since the gear box would become dis-

4
torted.
Heat up the gear box (7) where the 3
flange is located, with a hot air blower.
Insert a flat steel (5) between the two
2
screws (4) and remove the flange (3). 1
☞ Attention: left-handed thread!

3 Remove the spindle sleeve (6) with

the washers (A) and (9) as well as the
holder (8). D C B A 9 8
4 Remove the percussion body (C) with the
O-ring (D) and the gasket (B) from the
spindle sleeve (6), if necessary.

Detaching the 1 Remove the two screws (4) and take off 4
connecting rod the service cover (3) with the gasket (2).
2 Remove the connecting rod (7) from the 3
shaft (5). 2
5
3 Pull out the connecting rod (7) together
with the cylinder (8).

5
4 Remove the cylindrical bolt (1) from the
cylinder (8).
5 Pull off the bearing (6) from the connecting
rod (7) with aid of an interior extractor.
6
1 7
8
 Repair Instructions No.176.11/96 PAGE

PB 6S 3
Removing the 1 Loosen the two screws (1) and remove the
handle housing (2). A
2 Loosen the screws (6) and remove the
plate (5).
3 Remove the handle (7) including the
switch (E) (old model), with the lid (D) (soft
grip).
4 Loosen the screw (C) and detach the
lid (D). B
5 C
D
☞ Only applicable for newer switches: 9

6
a
first lever off the lid, then loosen the top 8
screw. 7
b
6 E
6 Remove the rubber stops (8) and (4).
7 Remove the connection cable (F) with the 5
cable entry sleeve (3) from the switch (E)
and remove the switch from the hand- 4
grip (7).
e
8 Loosen the screws (9) and pull off the 3
guard (B) from the gear box (A). d

2 b a

F
1

Removing the 1 Loosen the screws (1) and remove the

carbon brushes carbon brush covers (2).
2 Lift the respective brush spring from the
carbon brushes (5) and place them on top
of the brush holders.
3 Pull the respective cable lug from the car-
bon brushes (5) and pull out the carbon
brushes.
4 Loosen the four screws (3) and pull off the
motor housing (9) with the electric field (8) 7

7
and the air deflector ring (7).
5 Remove the air deflector ring (7).
6 Remove the electric field (8) from the mo- 8
tor housing (9) (if necessary, hit the motor
housing lightly with a plastic hammer), c
c
d e f
watch out for the rubber stops (6) which
might fall out. 6
7 Remove the carbon brush holders (4). 5
4 9
3 f

2
1
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PB 6S 4
Dismantling the 1 Loosen the screws (4) and (D). 8
bearing end plate Loosen the bearing end plate (6) by hitting
of the gear box the gear box with a plastic hammer and re-
move it.
7 9
2 Pull the armature (9) from the bearing end
plate (6) (if necessary, hit the bearing end
plate lightly with a plastic hammer) and re-

8
move the bearing bush (C) from the ball
bearing (B). A
6 B
3 Press off the ball bearing (B) and remove C
the insulating disc (A). 4 5
3
4 Remove the O-ring (3) and the washer (5).
Press off the ball bearing (2) and remove 2
the seal ring (1). 1
5 Remove the gasket from the bearing end D
plate (6) and take out the insert (7).
6 Pull out the needle bearing (8) with aid of
an interior extractor.

Detaching the 1 Remove the locking washer (1).

eccentric shaft
2 Pull off the toothed wheel (2) with
aid of a pulling off device
(service tool 9170 0314 440).
3 Remove the key (7) from the shaft (5).

9
4 Remove the locking washer (3) and pull
out the shaft (5); if necessary, press the 6
shaft through the opening in the gear box
with aid of a suitable mandrel. 5
5 Press the ball bearing (4) from the shaft. 7
6 Remove the O-ring (6) from the gear box. 4
3
2
1
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PB 6S 5
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. When carrying out manitenance, all worn parts must be changed.
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
A Cover with red grease (total 60 g)
B Generously cover with blue grease (total 60 g)

A A

B
A

A A AA
B

A B

B B

Torques Screws in plastic 2,0 Nm

Screws in metall 3,0 Nm
 Repair Instructions No.176.11/96 PAGE

PB 6S 6
Assembly
Mounting the 1 Press the bearing (5) into the connecting
connecting rod rod (6).
2 Fit the O-ring (1) to the percussion 4 5
body (2).
3 Push the percussion body (2) together
with the gasket (3) into the cylinder (7).
4 Fit together the cylinder (7) with the con-
necting rod (6) and put the cylindrical
bolt (4) through the two borings.
1 2 3

7 6
1
Mounting the 1 Insert the O-ring (A) into the gear box (6).
eccentric shaft 8
2 Press the ball bearing (4) onto the
shaft (5). 7 9
3 Insert the cylinder with the connecting rod
(see step 1) into the gear box (6).
6
4 Insert the shaft (5) into the gear box (6)
from below and fix it to the con rod bear-
ing.
5 Mount the locking washer (3). Fit the

2
key (B) to the shaft (5). A
6 Fit the toothed wheel (2) with the collar
facing the shaft and press it on. 5
B
☞ Steady the eccentric shaft with a suita-
ble mandrel which is pushed through 4
the opening in the gear box (otherwise
the shaft gets pushed in too far). 3
2
7 Secure the toothed wheel (2) with the
locking washer (1). 1
8 Fill the gear box (6) with grease through
the top opening according to the lubrica-
tion chart.
9 Fasten the gasket (9) and the service cov-
er (7) with the screws (7).
 Repair Instructions No.176.11/96 PAGE

PB 6S 7
Mounting the 1 Press the needle bearing (8) into the bear- 8
bearing end plate ing end plate (6).
of the gear box
2 Place the insert (7) in the bearing end
plate (6) (mind the right position!) and fit 7
the gasket.
9
3 Push the seal ring (1) over the

3
armature (9) and press on the needle
bearing (2). A
6 B
4 Mount the O-ring (3) and the washer (5).
5 Fit the insulating disc (A) and the ball 4 5 C
bearing (B) to the armature (9). 3
6 Fit the bearing bush (C) to the ball bear- 2
ing (B) and insert the armature (9) through 1
the gear box cover (6) turning it.
7 Fasten the screws (4) and (D). D

Mounting the 1 Insert the carbon brush holders (4) into the
carbon brushes motor housing (9) and screw them down
(do not yet fasten them completely).
Push the adjustment tool (service tool
9170 0232 60) from the outside through
the carbon brush holders (4) and adjust
the carbon brush holders.
2 Screw down the carbon brush holders (4)
and remove the adjustment tool.
3 Insert both rubber stops (6). 7
4 Insert the field (8) into the motor hous-

4
ing (9) and fit the air deflector ring (7)
(mind the right position!).
5 Fasten the motor housing (9) to the gear 8
box with the screws (3). c
c d e f
6 Fit the cable lugs of the carbon
brushes (5) to the field (8). 6
7 Insert the carbon brushes (5) into the car- 5
bon brush holders (4). 4 9
8 Pull up the brush springs of the carbon
brush holders (4) by the hook and push 3 f
them over the carbon brushes (5).
9 Fasten the carbon brush covers (2) with 2
the screws (1). 1
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PB 6S 8
Mounting the 1 Push the guard (B) over the gear box (A)
handle and fasten it with the screws (9). A
☞ Should the switch (E) be damaged,
replace by a new one
(reversion kit 917 0320 670).

2 Connect the cable (F) and the cable entry

sleeve (3) with the switch (E) and mount
them in the handle (7).
B
3 Connect them according to the wiring dia-
gram. C
4 Mount the rubber stops (8) and (4). 9 D

5
a
8
5 Fasten the switch (E) to the handle (7) 7
with screws and mount the lid (D) (soft b
grip).
6 E
6 Fasten the plate (5) with screws (6). 5
7 Push the housing (2) over the gear box.
4
☞ Take care that the contacts in the
housing grasp the gear box contacts.
e
3
8 Fasten the housing with the screws (1). d

2 b a

F
1

Mounting the 1 Push the spindle holder (7) and the wash-
flange ers (8) and (9) over the spindle sleeve (6).
5
2
4 6
☞ Apply Omnifit 80 to the flange (3) and
screw it down (left-handed thread).
4
3 Fasten two hardened screws (4) in the
flange (3). (They have to be removed be-

6
fore further assembly.)
Fasten the machine in a vice. Do not fas-
ten the machine too tight since the gear 3
box would become distorted.
Insert a flat steel (5) between the two
2
screws (4) and screw down the flange (3). 1
4 Insert the sleeve (2) and the rubber
ring (1) into the flange (3).

9 8 7
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PB 6S 9
Assembling the 1 Insert the recoil ring (7), the spacer (8) and
tool acceptance the O-ring (9) into the flange (see step 6). 5 6
2 Insert the snap die (A) into the tool accept-
ance (4). 1 2 3 4

7
3 Insert the tool acceptance completely with
the snap die (A), the spacer (5) and the
gasket (6) into the gear box.
4 Fit the adapter sleeve (2) and fasten it with
the five screws (B).
5 Insert the four balls (1) into the adapter
sleeve (2). 9 8 7
B A

Mounting the ball 1 Fit the locking bolt (4) together with the
holding device ball holding device (5).
2 Fit the pressure spring (6) and the retain- 1 2 3
ing plate (2), depress them and insert the

8
locking levers (3).
3 Mount the locking sleeve (1).

6 5 4

Mounting the 1 Mount the damper (7) and the damping el-
auxiliary handle ement (8) and secure them with the lock- 3 4
ing ring (9).
2 Fit the rubber sleeve (A). 2
3 Push back the rubber sleeve (A) and
mount the rubber bushing (5).
5
4 Press the clamping ring (1) and place the

9
auxiliary handle (4) on the clamping 6
ring (1).
1
5 Insert the screw (6) through the clamping
ring (1) and the auxiliary handle (4).
6 Push the washer (3) over the screw (6).
7 Secure the screw (6) with the nut (2).

A 9 8 7

Test Run Test run the machine and pay attention to noises.

Electrical Test Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).