Atlas Copco PN 3500 Setup guide

1
PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Special Tools
Required
■ Forcing disks 4931 599 021
■ Special pliers 4931 599 057
■ (Dis-) Assembly tool 4931 5990 84
■ Sleeve 4931 599 038
■ Screw locking device Omnifit 80 4931 945 651
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
Pullthecarbonbrushcablestogetherwith
the carbon brushes (2) from the housing.
Only applicable
for PN 3500:
Dismantling the
SDS-Plus-recep-
tion
1
Remove the rubber cap (1).
2
Remove the spacer (2).
3
Depress the sliding sleeve (4) and lever
off the locking ring (3) with aid of a screw-
driver.
4
Remove the sliding sleeve (4) and the re-
taining ring (5).
5
Depress the retaining disk (7) and press
out the ball (6) with aid of a screwdriver or
remove it with a magnet.
6
Remove the retaining disk (7) and the
spring (8).
1
2
3
4
5
6
3
2
1
1 2 3 5
6 7 8
4
2

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PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Only applicable
for PN 3500 X:
Dismantling the
FIXTEC-recep-
tion
1
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.
2
To remove the balls (4) (six pieces):
☞
Depress the seal ring (6) and remove
the balls with aid of a magnet.
3
Remove the remaining parts:
- seal ring (6)
- outer spring (7)
- ejector ring (5)
- inner spring (8) and
- washer (9).
Detaching the
gear housing
1
Switch the lever (4) to the "0"-position and
break it off with aid of pliers. The lever (4)
gets destroyed.
☞
Should this not be possible, fix the le-
ver (4) in a vice and break it off by mov-
ing the machine to and fro. Remove
any broken part from inside the ma-
chine.
2
Remove the four housing screws (1).
3
Only applicable for PHE 3500 X:
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 (3).
4
Remove the complete spindle sleeve (2)
from the cylinder.
1
2
3
5 6 7 8 9
42
2
1 3
5
2
4
3
1 2
5 4 3
4

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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Removing the
striker
1
Place the spindle vertically.
2
Briefly hit the plunger (1) with a mandrel.
The striker (2) comes free.
Dismantling the
spindle (remov-
ing the outer
parts)
1
Removing the rear thrust bearing (7):
Lever off the special locking ring (8) with
aid of a screwdriver.
2
The thrust bearing can be removed in the
following component parts:
- washer
- thrust bearing washer
- two compensating washers and
- profile ring with damper O-ring.
3 Remove the retaining disk (6) and the
locking slide (5).
4
Removing the spindle wheel (3):
Press the spindle wheel (3) with a sleeve
against the disk springs (1) - the locking
ring (4) is released and can be removed
with pliers. Remove the spindle wheel (3).
5
Remove the ratchet (2) and the disk
springs (1).
Dismantling the
spindle (remov-
ing the inner
locking ring)
1
☞
In the middle of the spindle (1) there
arefourdeairingholesand oneservice
boring (3).
Theserviceboring(3) has the smallest
diameter.
2 Turn the round wire locking ring (2) with
aid of the service tool (4931 599 084)
suchthatoneendprojectstheservicebor-
ing (3) by approx. 2 mm.
3
Put a screwdriver through the service
boring (3) and place it under the locking
ring (2).
4
Move the screwdriver to and fro and at the
sametimeturnthelocking ring (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.
5
Press the locking ring (2) from the spindle.
1
2
5
1 72 3 5 6 84
1
3
4
6
1
2 3
7

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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Only applicable
for PN 3500:
Dismantling the
spindle (remov-
ing the inner
parts)
1
Press the following parts from the
spindle (1):
- washer (6)
- pressure sleeve (5)
- plunger (4) and
- brake disk (2).
2
Remove the O-rings (3) and (7).
Only applicable
for PN 3500 X:
Dismantling the
spindle (remov-
ing the inner
parts)
1
Press the following parts from the
spindle (1):
- washer (9)
- pressure sleeve (6)
- plunger (5)
- brake disk (4) and
- pressure sleeve (3).
2
Remove the O-rings (2), (7) and (8).
Removing the
back 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 back gear shaft (5) by turning
or canting it (see arrow in illustration).
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 5 6
7
4
8
1 2
35 6
7 8
9
4
8
12
3
5
4
9

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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Dismantling the
back gear shaft
1
Remove the rubber O-ring (6).
☞
Attention! The rubber O-ring (6) fits
tightly and is difficult to remove.
2
Remove the washer (5) and the thrust
bearing (4) as well as the disk (3).
3
Press off the back gear wheel (2).
4
Remove the remaining parts from the
back gear shaft (B):
- tumble drive (1)
- washer (7)
- coupling box (8)
- spring (9) and
- washer (A).
Removing the
angle drive 1Remove the locking ring (1) with aid of special pliers.
2Remove the angle drive (4) together with
the disk (2), the washers (3) as well as the
support ring (5).
If necessary, hit the gear housing lightly
with a plastic hammer for support.
3☞Depending on the tolerance of the
bearing the tool can be equipped with
two or three washers (3).
4If this bevel wheel will be used again,
please note the number of the washers.
Mount the same number when re-assem-
bling.
Removing the
motor cover 1Loosen the four screws (1) and remove
the motor cover (2).
2Remove the rubber cap (3) in case of
damage.
B A
9 7
1 2 3 54 6
8
10
1 3
4 5
2
11
3
2
1
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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Dismantling the
handle 1Expel the pin (B).
2Pull the field supply cables (A) from the
contacts and remove them from the field
housing.
3Loosenthescrew(8)andremovethegear
cover (9).
4Loosen the screws (6) and remove the
handle cover (5).
5Lever off the locking ring (1) with aid of
special pliers and remove it together with
the washer (2).
6Pull the handle back slightly and remove
the AVS-rubber (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
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Repair Instructions No.179.11/97
PN 3500 / 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 support.
Removing and
dismantling the
armature
1Remove the seal ring (8).
2Lever off the angle (1) and remove the sil-
icone buffer (2).
3Pull out the complete armature (7).
4Press off the toothed wheel (3).
5Remove the washer (4) and the seal
ring (5).
6Apply the pulling-off device below the
ball bearing (6) and press off the ball bear-
ing (6).
Removing the
field 1Remove the air deflector plate (1) and
damaged 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
1 2 3
5
6
7
8
4
16
5
4
3
1
2
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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Maintenance
General It is recommended to regularly submit the tool to maintenance, or as soon as the hammer mechanism
gets weak, 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 device
Spindle sleeve screws (3) 6,0 Nm + screw locking device
Screws (4) 2,5 Nm
Motor screws (5) 2,5 Nm + screw locking device
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.179.11/97
PN 3500 / 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
B Thinly cover with a total of 14 g Tivela grease
A
A
B
A
B
B
B
B
A
A
B
B
A
A
A
A
A
A
B

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Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Assembly
Mounting the
field 1Fit the centring ledges (3) to the field (4) (take care of the right position; see illustra-
tion).
2Insert the field (4) into the motor hous-
ing (5) (hit the back of the field housing
lightly with a plastic hammer for support).
3If necessary, insert new silicone
buffers (2) into the air deflector plate (1).
4Insert the air deflector plate (1).
☞Take care of the right position: see il-
lustration.
Assembling and
mounting the
armature
1Push the bearing (6), the washer (4) and
the seal ring (5) over the armature shaft.
☞Take care of the right position: the
small boring-Ø must face the toothed
gear.
2Press on the toothed gear (3) as far as it
will go.
3Insert the complete armature (7) into the
field.
4Fit the silicone buffers (2) to the field hous-
ing.
5Fix the armature with the angle (1) inside
the field housing.
6Fit the seal ring (8) to the field housing.
7☞The armature must turn easily.
5
4
3
1
2
1
1 2 3
5
6
7
4
8
2

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Repair Instructions No.179.11/97
PN 3500 / 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).
Mounting the
electric
components
1Connect all cables with the switch accord-
ing to the wiring diagram.
2Lead the field supply cables (3) through
the handle as shown in illustration.
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
5
4

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PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Mounting the
handle 1Fix the handle bolt (7) in the hous- ing (10 Nm).
2Push the handle (4) over the bolt and fix
the AVS-rubber (3) with the washer (2)
and the locking ring (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)andsecureitwiththe
screw (8).
6Lead the field supply cables (A) through
the channels of the field housing and con-
nect them with the field (connect them di-
agonally).
Mounting the
motor cover 1Fit the motor cover (2) (mind the right
position) 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.179.11/97
PN 3500 / PN 3500 X
Mounting the
angle drive 1Insert the support ring (5).
2Greasetheangledrive(4)andinsertit into
the motor housing by turning it slightly.
3Insert the washers (3) and (2).
☞Depending in the tolerance of the bear-
ing, two or three washers (3) might be
needed. For assembly, use the same
amount of washers as were removed
when dismantling.
4Fit the locking ring (1).
Assembling the
back gear shaft 1Push the following parts over the back
gear shaft (1) in this order:
- washer (B)
- spring (A)
- coupling box (9)
- washer (8) and
- tumble drive (2).
2Press on the back gear wheel (3); the
smooth surface must face the tumble
drive (2).
☞The play between the back gear
wheel (3)andthetumbledrive(2)must
be set to 0.05 mm.
3Lightlygrease thethrustbearing (5)andfit
it together with the disk (4) to the back
gear wheel (3).
4Fit the disk (6) and check the distance "X":
☞If the distance is more than 100.5 mm,
do not fit the disk (6).
☞Ifthedistanceislessthan100.5mm,fit
another disk (6) and check the dis-
tance again.
5Insert the O-ring (7).
1 2 43
1 2 3
5
7
2 3 6
0,5 mmX
6
5
4
3
7
2
89A
1B
8

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PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Mounting the
back gear shaft
and the cylinder
1Insertthe twodisks(3) andthebolt (2)into
the cylinder (1).
2The back gear assembly (4) can only be
inserted as follows:
Put together the cylinder (1) and the back
gear assembly (4) for adjustment before
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 1Insert the bearing ring (1) into the motor
housing (do not yet insert it all the way,
mind the right position).
2Pressinthebearingring(1)asfarasitwill
go.
Only applicable
for PN 3500:
Assembling the
spindle (mount-
ing the inner
parts)
1Fit the O-rings (8) to the pressure
sleeve (5).
2Press the brake disk (2) into the spin-
dle (1). Mind the right position!
3Mount the O-ring (3) on the plunger (4)
and insert the plunger into the pressure
sleeve (5). Insert the pressure sleeve into
the spindle.
4Insert the washer (6) into the spindle and
mount it on top of the O-ring.
5Press the locking ring (7) (round wire ring)
with aid of a used cylinder into the spindle
until the locking ring engages.
☞Carry out a visual check!
1 2
3
5 4
9
1
10
1 2
3 5
8
4
76
11

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PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Only applicable
for PN 3500 X:
Assembling the
spindle (Mount-
ing the inner
parts)
1Insert the O-rings (2) and (7) into the pres-
sure sleeves (3) and (6). Fit the O-ring (8)
to the pressure sleeve (6).
2Press the pressure sleeve (3) into the
spindle (1).
3Push the brake ring (4) and the pressure
sleeve (6) over the plunger and insert
them together into the spindle (1).
4Insert the washer (9) into the spindle and
mount it on top of the O-ring (8).
5Press the locking ring (A) into the spindle
with aid of a special tool until the locking
ring engages.
☞Carry out a visual check!
Assembling the
spindle
(Mounting the
outer parts)
1Mount the disk springs (1) with the bulg-
ings head-on (see illustration).
2Mounting the clutch:
Mount the ratchet (2) with indentations
against the toothing of the spindle
wheel (3).
3Fit the locking ring (4) and press it against
the disk springs with aid of a press.
4Fit the locking slide (5) and the retaining
disk (6). Take care of the right position!
5Mounting the rear thrust bearing (7):
- washer
- thrust bearing washer
- two compensating washers and
- profile ring with damper O-ring.
6Secure the rear thrust bearing (7) with a
special locking ring (8).
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 back gear
shaft (5) and let it engage in the locking
slide (3).
3Push the planetary gear (7) over the
back gear shaft (5) and fit it into the ring
gear (6).
4Push the straight pin (8) through the lock-
ing slide (3) and insert it into the motor
housing (4).
1 2
35 6
7 8
9
4
A
45
11
1 72 3 5 6 84
12
1 2
8 7 6
3 4
5
13

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PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
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)
4Fit the switch lever (5) (mount it in the
„drilling“ position).
☞The pin must grasp the elongated hole
in the locking slide.
Only applicable
for PN 3500:
Mounting the
SDS-plus-recep-
tion
1Insert the spring (8) and the retaining
disk (7).
2Depress the retaining disk (7) and insert
the ball (6).
3Fit the retaining ring (5) and the sliding
sleeve (4).
4Depress the sliding sleeve (4) and insert
the seal ring (3) into the pass.
5Fit the spacer (2).
6Push down the sliding sleeve and fit the
rubber cap (1).
1
2 3
5
4
14
1 2 3 5
6 7 8
4
15

17
PAGE
Repair Instructions No.179.11/97
PN 3500 / PN 3500 X
Only applicable
for PN 3500 X:
Mounting the
FIXTEC-recep-
tion
1Press in the seal ring (2) with aid of the
sleeve (1) (service tool) until it engages.
2Fit the following parts in the below order:
- washer (9)
- inner spring (8)
- outer spring (7) and
- locking ring (6).
3Depress the locking ring (6) and insert the
balls (4).
4Insert the ejector ring (5).
5Depress the locking ring (6) (cover the
balls with your hand so they cannot fall
out) and press in the ejector ring (5) with
aid of a used SDS-plus adapter.
6Press a locking ring into the spindle in or-
der to secure the ejector when mounting
the locking sleeve (3).
7Fix the locking sleeve (3).
8Remove the locking ring fitted to secure
the ejector.
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
respective carbon brush holder (4)
and place the spring (2) on the carbon
brush (1). Fit the flat plug.
3Screw down the respective service cov-
ers (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
5 6 7 8
4
A
92
16
1 2
3
56
1
4
17