Atlas Copco PN 3500 X Einrichtungshandbuch

Repair Instructions No.187.11/00

PN 3500 X

Atlas Copco

Electric Power Tools Ltd.

4939 5232 01

(11/00)

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

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).

Pullthe carbonbrushcables togetherwith

the carbon brushes (2) from the housing.

Dismantling the

FIXTEC-recep-

tion

Remove the locking ring (4).

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.

To remove the balls (5) (six pieces):

☞

Depress the seal ring (6) and remove

the balls with aid of a magnet.

Remove the remaining parts:

- seal ring (6),

- pressure spring (7),

- disc (8).

25678

PAGE

Repair Instructions No.187.11/00

PN 3500 X

Detaching the

gear housing

Remove two screws (5) from the holding-

down device (6) and lever off the switch le-

ver (4) with aid of a screwdriver.

Remove the four housing screws (1).

☞

Vertically insert the machine into a

mounting stand (4931 599 039).

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 (5).

Remove the complete spindle sleeve (2)

from the cylinder.

Removing

the striker

Place the spindle vertically.

Briefly hit the plunger (1) with a mandrel.

The striker (2) comes free.

5 6

1 2

3 4 5

PAGE

Repair Instructions No.187.11/00

PN 3500 X

Disassembling

the spindle

(removing the

outer parts)

Remove the locking washer (A).

Reduce the rear thrust bearing (9) to its

component parts:

- washer,

- O-ring,

- 2 compensating discs (thin)

and

- thrust bearing disc with washer (thick).

Remove the latch plate (8) and

the locking slide (7).

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!

Remove the clutch disc (2) and the cup

springs (1).

Ø 30

Ø 40

Ø 46

Ø 60

ca 50

ca 70

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.

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.

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

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.

Press the locking ring (2) from the spindle.

Disassembling

the spindle

(removing the

inner parts)

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

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 reduction gear shaft (5) by

turning or canting it (see arrow in illustra-

tion).

Completely remove the cylinder (1) and

the back gear.

Push out the bolt (2) by hand and remove

the two disks (3).

2 3

1 2 3 4

PAGE

Repair Instructions No.187.11/00

PN 3500 X

Dismantling the

reduction gear

shaft

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.

Remove the washer (6) and the thrust

bearing (discs (3), (4) and (5)).

Press off the reduction gear wheel (2).

Remove the following parts:

- wobble drive (1),

- coupling sleeve (B),

- pressure spring (A),

- disc (9).

Removing the

pinion shaft

Remove the locking ring (1).

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

Loosen the four screws (1) and remove

the motor cover (2).

Remove the rubber cap (3) in case of

damage.

1 2 3 54 7

3 4

PAGE

Repair Instructions No.187.11/00

PN 3500 X

Dismantling

the handle

Expel the pin (B).

Pull the field supply cables (A) from the

contacts and remove them from the field

housing.

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

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.

123

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

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).

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