Atlas Copco PN 3500 X Setup guide

Repair Instructions No.187.11/00
PN 3500 X
PN 3500 X
Atlas Copco
Electric Power Tools Ltd.
4939 5232 01
(11/00)

1
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Special Tools
Require
■ Forcing disks 4931 599 021
■ Special pliers 4931 599 057
■ (Dis-) Assembly tool 4931 5990 84
■ Sleeve 4931 599 038
■ Screw locking agent Omnifit 80 4931 945 651
■ Mounting stand 4931 599 039
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
carbon brushes
1
Loosen the two screws (6) on both sides
and remove the respective service cov-
ers (5).
2
Remove the cables (3) and pull the brush
holders (4) from the housing.
3 Put the springs (1) aside (see illustration)
and pull out the carbon brushes (2).
4
Pullthe carbonbrushcables togetherwith
the carbon brushes (2) from the housing.
Dismantling the
FIXTEC-recep-
tion
1
Remove the locking ring (4).
2
Removing the locking sleeve (2):
☞
Fix the locking sleeve (2) in a pulling-
off device (3) and press it out. At the
same time, press down the spindle (1)
with a suitable sleeve.
Or: Cut the locking sleeve (2) at the
side.
3 To remove the balls (5) (six pieces):
☞
Depress the seal ring (6) and remove
the balls with aid of a magnet.
4
Remove the remaining parts:
- seal ring (6),
- pressure spring (7),
- disc (8).
1
2
3
4
5
6
3
2
1
1
2
3
25678
4
2

2
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Detaching the
gear housing
1
Remove two screws (5) from the holding-
down device (6) and lever off the switch le-
ver (4) with aid of a screwdriver.
2
Remove the four housing screws (1).
3
☞
Vertically insert the machine into a
mounting stand (4931 599 039).
4
Open the locking ring (2) on the spindle
with aid of special pliers (5) (service tool)
and remove it together with the gear hous-
ing (3).
Removing
the spindle
1
Remove the two screws (1).
2 Remove the straight pin (5).
3
Remove the planetary gear (4) and the
ring gear (5).
4
Remove the complete spindle sleeve (2)
from the cylinder.
Removing
the striker
1 Place the spindle vertically.
2
Briefly hit the plunger (1) with a mandrel.
The striker (2) comes free.
1
7
2
5 6
3
4
3
1 2
3 4 5
4
1
2
5

3
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Disassembling
the spindle
(removing the
outer parts)
1
Remove the locking washer (A).
2 Reduce the rear thrust bearing (9) to its
component parts:
- washer,
- O-ring,
- 2 compensating discs (thin)
and
- thrust bearing disc with washer (thick).
3
Remove the latch plate (8) and
the locking slide (7).
4
Remove the spindle gear (4):
Press the spindle gear (4) with a sleeve
against the cup springs (1) – the spring
ring (6) is released and can be removed
with the pliers. Remove the disc (5). Re-
move the spindle gear (4) and the cylinder
pulleys (3).
Remove four balls (B).
☞
The dimensions for the sleeve can be
taken from the below illustration!
5
Remove the clutch disc (2) and the cup
springs (1).
Ø 30
Ø 40
Ø 46
Ø 60
90
ca 50
ca 70
6
1
8
3
7
9
1
4
6
2
A
5
4
6
B
6

4
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Disassembling
the spindle
(removing the in-
ner locking ring)
☞
In the middle area of the spindle (1)
there are four deairing holes and four
service borings (3).
The diameter of the service borings (3)
is smaller than that of the deairing
holes.
1
Turn the round wire locking ring (2) with
aid of the service tool (4931 599 084)
suchthat one end projects the service bor-
ing (3) by approx. 2 mm.
2
Put a screwdriver through the service
boring (3) and place it under the locking
ring (2).
3
Move the screwdriver to and fro and at the
sametime turnthe lockingring (2)with aid
of the service tool in direction of arrow.
☞
Turn the locking ring (2) until it is com-
pletely levered off the groove.
4
Press the locking ring (2) from the spindle.
Disassembling
the spindle
(removing the
inner parts)
1
Remove the following parts from the spin-
dle (1):
- thrust collar (8),
- O-ring (7),
- radial seal ring (6),
- sleeve (5),
- snap die (4),
- brake disc (3),
- seal ring (2).
Removing the
reduction gear
shaft and the
cylinder
1
Pull out the bearing housing (4).
If necessary, loosen the bearing hous-
ing (4) by hitting the gear housing lightly
with a plastic hammer.
2
Remove the reduction gear shaft (5) by
turning or canting it (see arrow in illustra-
tion).
3
Completely remove the cylinder (1) and
the back gear.
4 Push out the bolt (2) by hand and remove
the two disks (3).
1
2 3
7
1 2 3 4
76
5
8
8
12
3
5
4
9

5
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Dismantling the
reduction gear
shaft
1
Remove the O-ring (7).
☞
Attention! The O-ring (7) fits tightly and
only serves to lock the discs during
(dis-) assembly of the reduction gear
shaft.
2 Remove the washer (6) and the thrust
bearing (discs (3), (4) and (5)).
3
Press off the reduction gear wheel (2).
4
Remove the following parts:
- wobble drive (1),
- coupling sleeve (B),
- pressure spring (A),
- disc (9).
Removing the
pinion shaft
1
Remove the locking ring (1).
2
Remove the pinion shaft (3) with disc (2)
and ring (4).
☞
If necessary, hit the gear housing light-
ly with a plastic hammer for support.
Removing the
motor cover
1
Loosen the four screws (1) and remove
the motor cover (2).
2
Remove the rubber cap (3) in case of
damage.
8
9A
1 2 3 54 7
B
6
10
1
3 4
2
11
3
2
1
12

6
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Dismantling
the handle
1
Expel the pin (B).
2 Pull the field supply cables (A) from the
contacts and remove them from the field
housing.
3 Loosenthescrew(8)andremovethegear
cover (9).
4Loosen the screws (6) and remove the
handle cover (5).
5Remove the washers (1) and (2).
6Slightly pull back the handle and remove
the damper element (3).
7Remove the handle (4).
8Unscrew and remove the handle bolt (7).
Detaching
the electric
components
1Unscrew the strain relief (1).
2Remove the following parts:
- switch (2)
- capacitor (4)
- mains cable (5) and
- field cable (3).
123 5
6
7
8
9
4
BA
13
4
1
2
3
5
14

7
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Removing
the motor 1Loosen the screws (1) and (4) and pull out the motor (3).
☞If necessary, hit the motor housing (2)
lightly with a plastic hammer for sup-
port.
Removing and
dismantling the
armature
1Remove the seal ring (A) and the
O-ring (2).
2Pull out the bearing cover (1) and remove
the holing-down devices (B).
3Pull out the complete armature (8).
4Disassemble the armature (8) as follows:
- press off the pinion shaft (3),
- remove spacer (4) and
- sleeve (5),
- press off the ball bearing (6) and
the grooved ball bearing (9) with
forcing discs,
- remove the insulating disc (7).
Removing
the field 1Remove the air deflector ring (1) and dam- aged silicone buffers (2).
2Pull the field (4) from the motor hous-
ing (5) and remove the centring
ledges (3).
☞If necessary, hit the motor housing
lightly with a plastic hammer
for support.
1
2
3
4
15
123
5
6
8
A
4
7
B
9
16
5
4
3
1
2
17

8
PAGE
Repair Instructions No.187.11/00
PN 3500 X
Maintenance
General It is recommended to regularly submit the tool to maintenance, or as soon as the hammer mechanism
getsweak, or when the carbon brushes switch off.When carrying out maintenance all parts of the main-
tenance set must be exchanged. Use the respective maintenance set provided for each machine.
Torques Handle cover screws (1) 1.2 Nm
Motor screws (2) 2.5 Nm + screw locking agent
Spindle sleeve screws (3) 6.0 Nm + screw locking agent
Screws (4) 2.5 Nm
Motor screws (5) 2.5 Nm + screw locking agent
Motor cover screws (6) 1.8 Nm
Handle bolt (7) 10.0 Nm
21
1
34
5
6
7
1

9
PAGE
Repair Instructions No.187.11/00
PN 3500 X
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 Thickly cover with a total of 31 g Darina grease (4931 622 229).
B Thinly cover with a total of 14 g Tivela grease (4931 215 436).
C Insert a total of 0.5 g Turmopast grease into the wobble gear boring (4931 379 848).
A
A
B
A
B
B
B
B
A
A
C
A
A
A
A
A
A
B
C