Atlas Copco PN 3500 Setup guide

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

Loosen the two screws (6) on both sides

and remove the respective service cov-

ers (5).

Remove the cables (3) and pull the brush

holders (4) from the housing.

Put the springs (1) aside (see illustration)

and pull out the carbon brushes (2).

Pullthecarbonbrushcablestogetherwith

the carbon brushes (2) from the housing.

Only applicable

for PN 3500:

Dismantling the

SDS-Plus-recep-

tion

Remove the rubber cap (1).

Remove the spacer (2).

Depress the sliding sleeve (4) and lever

off the locking ring (3) with aid of a screw-

driver.

Remove the sliding sleeve (4) and the re-

taining ring (5).

Depress the retaining disk (7) and press

out the ball (6) with aid of a screwdriver or

remove it with a magnet.

Remove the retaining disk (7) and the

spring (8).

1 2 3 5

6 7 8

PAGE

Repair Instructions No.179.11/97

PN 3500 / PN 3500 X

Only applicable

for PN

3500

Dismantling the

FIXTEC-recep-

tion

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.

To remove the balls (4) (six pieces):

☞

Depress the seal ring (6) and remove

the balls with aid of a magnet.

Remove the remaining parts:

- seal ring (6)

- outer spring (7)

- ejector ring (5)

- inner spring (8) and

- washer (9).

Detaching the

gear housing

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.

Remove the four housing screws (1).

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

Remove the two screws (1).

Remove the straight pin (5).

Remove the planetary gear (4) and the

ring gear (3).

Remove the complete spindle sleeve (2)

from the cylinder.

5 6 7 8 9

1 3

1 2

5 4 3

PAGE

Repair Instructions No.179.11/97

PN 3500 / PN 3500 X

Removing the

striker

Place the spindle vertically.

Briefly hit the plunger (1) with a mandrel.

The striker (2) comes free.

Dismantling the

spindle (remov-

ing the outer

parts)

Removing the rear thrust bearing (7):

Lever off the special locking ring (8) with

aid of a screwdriver.

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.

Remove the retaining disk (6) and the

locking slide (5).

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).

Remove the ratchet (2) and the disk

springs (1).

Dismantling the

spindle (remov-

ing the inner

locking ring)

☞

In the middle of the spindle (1) there

arefourdeairingholesand oneservice

boring (3).

Theserviceboring(3) has the smallest

diameter.

Turn the round wire locking ring (2) with

aid of the service tool (4931 599 084)

suchthatoneendprojectstheservicebor-

ing (3) by approx. 2 mm.

Put a screwdriver through the service

boring (3) and place it under the locking

ring (2).

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.

Press the locking ring (2) from the spindle.

1 72 3 5 6 84

2 3

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)

Press the following parts from the

spindle (1):

- washer (6)

- pressure sleeve (5)

- plunger (4) and

- brake disk (2).

Remove the O-rings (3) and (7).

Only applicable

for PN

3500

Dismantling the

spindle (remov-

ing the inner

parts)

Press the following parts from the

spindle (1):

- washer (9)

- pressure sleeve (6)

- plunger (5)

- brake disk (4) and

- pressure sleeve (3).

Remove the O-rings (2), (7) and (8).

Removing the

back gear shaft

and the cylinder

Pull out the bearing housing (4).

If necessary, loosen the bearing hous-

ing (4) by hitting the gear housing lightly

with a plastic hammer.

Remove the back gear shaft (5) by turning

or canting it (see arrow in illustration).

Completely remove the cylinder (1) and

the back gear.

Push out the bolt (2) by hand and remove

the two disks (3).

1 2

3 5 6

1 2

35 6

7 8

PAGE

Repair Instructions No.179.11/97

PN 3500 / PN 3500 X

Dismantling the

back gear shaft

Remove the rubber O-ring (6).

☞

Attention! The rubber O-ring (6) fits

tightly and is difficult to remove.

Remove the washer (5) and the thrust

bearing (4) as well as the disk (3).

Press off the back gear wheel (2).

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

1 3

4 5

PAGE

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

PAGE

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

PAGE

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

PAGE

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

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