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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PAGE
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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PAGE
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
12

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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
14

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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
17

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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