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

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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

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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

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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

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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

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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

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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

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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

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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

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Repair Instructions No.187.11/00
PN 3500 X
Assembly
Mounting
the field 1Place the centring ledges (3) on the field (4) (mind the right position, see illus-
tration).
2Insert the field (4) into the motor hous-
ing (5), or press it in. If support is needed,
lightly hit the motor housing with a plastic
hammer from behind.
3If necessary, insert new silicone buff-
ers (2) into the air deflector ring (1).
4Insert the air deflector ring (1).
☞The rounded corners of the air deflec-
tor ring (1) must face the centring
ledge (3).
Assembling and
mounting the
armature
1Assemblethearmaturebypressingonthe
following parts:
- the grooved ball bearing (9),
- insulating disc (7),
- ball bearing (6),
- sleeve (5),
- spacer (4),
- press on the pinion shaft (3).
2Insert the completely assembled arma-
ture (8) into the field.
3Put the holding-down devices (B) on the
field housing.
4Fixthearmaturewith the bearingcover(1)
in the field housing (insert it in direction of
arrow).
☞The armature must rotate easily.
5Put the seal ring (A) on the field housing
and mount the O-ring (2).
5
4
3
1
2
1
123
6
7
8
A
4
B
9
5
2

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Repair Instructions No.187.11/00
PN 3500 X
Mounting
the motor 1Insert the motor (1) into the motor hous- ing (3) (take care of the right position: the
lug (4) must fit into the relief of the motor
housing).
2Fasten the motor with the screws (2)
and (5) (2.5 Nm).
☞Use new screws (2) and (5) with micro
encapsulation or cover the used
screwswithscrewlockingagentbefore
assembly.
Mounting
the electric
components
1Connect all cables with the switch accord-
ing to the wiring diagram.
2Leadthe field supply cables (3)(black and
yellow) through the handle as shown in il-
lustration.
3Insert the switch (2) and the capacitor (4)
into the provided relief.
4Insert the mains cable (5) into the handle.
5Screw down the strain relief (1) (1 Nm).
2
3
4
5
1
3
4
1
2
3
5yellow
black
4

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Repair Instructions No.187.11/00
PN 3500 X
Mounting
the handle 1Cover the handle bolt (7) with locking agent, insert it into the housing and screw
it down (10 Nm).
2Push the handle (4) over the bolt and fas-
ten the damper element (3) with the wash-
ers (2) and (1).
3Fasten the handle cover (5) with the
screws (6).
4Fix the handle with the bolt (B). Press in
the bolt (B) or knock it in with a plastic
hammer.
5Fitthegearcover(9) and secure it withthe
screw (8).
6Leadthefieldsupply cables (A)(blackand
yellow) through the channels of the field
housing as shown in illustration. Connect
them to the field diagonally.
Mounting the
motor cover 1Fit the motor cover (2) (mind the right po- sition) and secure it with the screw (1)
(1.8 Nm).
☞Apply glue to the back of the rubber
cap (3) and fix it in the motor cover (2).
123 5
6
7
8
9
4
BA
5
3
2
1
6

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Repair Instructions No.187.11/00
PN 3500 X
Mounting the
angle drive 1Insert the support ring (4).
2Greasethe angledrive(3)andinsertitinto
the motor housing by turning it slightly.
3Put on the disc (2) and mount the locking
ring (1).
Assembling the
reduction gear
shaft
1Assemble the reduction gear shaft (1) by
mounting the following parts:
- disc (9),
- pressure spring (A),
- coupling sleeve (B),
- wobble drive (1).
2Press on the reduction gear wheel (2).
The smooth surface must face the wobble
drive (1).
3Lightly grease the thrust bearing (4) and
put it together with discs (3) and (5) on the
reduction gear wheel (2).
4Fit the washer (6) and check the dimen-
sion “X1”: For control dimension “X1”:
☞Only insert disc “a” if the control dimen-
sion X1 is smaller than 100.42 mm.
5Insert the O-ring (7). It only serves as
mounting aid to keep the disc (6) locked.
6Check dimension “X2”: For control dimen-
sion “X2” applies:
☞Choose a suitable disc according to
control dimension X2 and insert it.
1 2
1
2
4
3
7
Control dimension X1/mm 99.97-100.42 100.43-101.10
Compensation (disc a) 1 x 0.5 –
Control dimension
X2/mm Compensation
Disc b:
1.0 mm Disc c: 0.4 mm Disc d : 0.2 mm
91.98 - 92.00 1x 1x
92.01 - 92.20 1x 1x
92.21 - 92.40 1x 1x
92.41 - 92.60 1x
92.61 - 92.80 2x
92.81 - 93.00 1x 1x
93.01 - 93.20 1x
93.21 - 93.40 1x
93.41 - 93.73 – –
8
9A
1 2 3 54 7
B
6
Control dimension X1
Control dimension X2
if necessary
+ Disc a
if necessary
+ Disc (s) b,c, d
8

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Repair Instructions No.187.11/00
PN 3500 X
Mounting the
reduction gear
shaft and the
cylinder
1Insertthetwodisks(3)and the bolt (2)into
the cylinder (1).
2The reduction gear shaft (4) can only be
inserted as follows:
Put together the cylinder (1) and the re-
duction gear shaft (4) for adjustment be-
fore mounting them.
☞Insert the tumble drive into the cylinder
and insert them together into the gear
box.
3Grease the striker (5) and insert it into the
cylinder (1).
Mounting the
spindle bearing 1Press the sleeve (1) into the motor hous- ing. Mind the right position!
Assembling the
spindle
(mounting the
inner parts)
1Insert the following parts into the spin-
dle (1):
- seal ring (2),
- brake disc (3),
- snap die (4),
- sleeve (5),
- radial seal ring (6),
- O-ring (7),
- thrust collar (8).
2Push the locking ring (9) into the spindle
and let it engage.
☞The cylinder (A) can be used for sup-
port.
Check the proper seat of the locking
ring: the first half of the cylinder bor-
ings (A) must be covered by the spin-
dle sleeve (1).
1 2
3
5 4
9
1
10
1 2
3
5 6
4
9
4
8
A
7
1
11

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Repair Instructions No.187.11/00
PN 3500 X
Assembling the
spindle
(mounting the
outer parts)
1Mount the cup springs (1) with the bulg-
ings head-on (see illustration).
2Mount the clutch disc (2).
3Insert four balls (B) into the spindle and
mount the spindle wheel (3) with the cylin-
der pulleys (A).
4Mount the disc (4) and secure it with the
spring ring (5).
5Mount the locking slide (6) and the latch
plate (7).
6Mount the rear thrust bearing (8):
- washer
- O-ring
- two compensating discs
- thrust bearing disc with washer.
7Mount the locking washer (9).
Mounting
the spindle 1Fit the spindle (2) to the motor housing (4) and fasten it with two additionally secured
screws (1) (6 Nm).
2Push the ring gear (6) over the reduction
gear shaft (5) and let it engage in the lock-
ing slide (3).
3Push the planetary gear (7) over the
reduction gear shaft (5) and fit it into the
ring gear (6).
Mount the disc (9) and further spacers, if
necessary.
4Push the straight pin (8) through the lock-
ing slide (3) and insert it into the motor
housing (4).
Mounting the
gear housing 1Insert the sleeve (1) (service tool) into the gear housing (2) (the sleeve protects the
rotary shaft seal in the gear housing from
damage during assembly).
2Fit the gasket (3) to the motor housing (4).
3Fit the gear housing (2) to the motor hous-
ing (4) and screw it down (2.5 Nm).
4Screw down the holding-down device (5)
and the switch lever (7) with two
screws (6) and push in the switch le-
ver (7).
☞The pin (8) of the switch lever must fit
into the long narrow hole of the locking
slider (9).
1 83 4 6 7 92
A
5
B
12
1 2
8 7 6
3 4
59
13
12 3
7
456
8
9
14

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Repair Instructions No.187.11/00
PN 3500 X
Mounting the
FIXTEC receiver 1Push in the locking ring (2) with aid of the sleeve (1) (service tool) and let it engage.
2Mount the following parts in the below or-
der:
- disc (8)
- pressure spring (7) and
- seal ring (6).
3Depress the seal ring (6) and insert six
balls (5).
4Mount the locking sleeve (4).
5Mount the locking ring (3).
Mounting the
carbon brushes 1Insert each carbon brush holder (4) into the housing and connect the cables (3)
with the field.
2Insert each carbon brush (1) into the re-
spective carbon brush holder (4) and
place the spring (2) on the carbon
brush (1). Fit the flat plug.
3Fasten the service covers (6) with
screws (5).
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).
1
2
3
4 5 6 7 9 8 2
15
1 2
3
56
1
4
16