Keyang KH-5000M Manuale utente

A/S Manual

(KH-5000M Disassembly/Assembly)

- 1 -

Contents

< How to deal with each type of defective impact >

< KH-5000 Disassembly/Assembly >

1. Clean and replace the carbon brush ····················································· 10

2. How to replace the cord/handle/switch ················································ 11

3. How to replace the armature ································································· 12

4. How to replace the stator/housing ························································ 13

5. How to replace the side handle ····························································· 14

6. How to replace the front cover/bit guide ·············································· 15

7. How to replace the cylinder case ·························································· 16

8. How to replace the connecting rod/piston ··········································· 17

9. How to replace the crank case ······························································ 18

10. How to replace the gear cover ···························································· 20

11. Grease supplying ················································································· 21

12. Dissembling the cylinder case ass’y ·················································· 22

- 2 -

EXPLODE IEW

- 3 -

PART LIST

No Code No PART NAME SPEC Q,ty

1 2072614 DUST CAP, KH-50M 1

2 2135072 RETAINER, KH-50M 1

3 2411818 SPRING, KH-50M 1

4 2412027 RETAINING RING(D32, C Type, A is) (D32, C Type, A is) 1

5 2110024 SELECTOR GUIDE, KH-50M 1

6 2110025 SELECTOR, KH-50M 1

7 2400816 HEX SOC HD B & PW(M4*16,COAT, Combination type) M4*16 5

8 2141514 CRANK CASE COVER(B), KH-5000 1

9 2416024 STEEL BALL(D6), KHD-50M D6 4

10 2032118 FRONT COVER, KH-50M 1

11 2412428 O-RING(C)(D2*42,NBR), KH-50H (D2*42, NBR) 2

12 2412398 O-RING(S28) 2

13 2032519 GUIDE PIN, KH-50M 2

14 2030210 BIT GUIDE, KH-5000M 1

15 2412447 O-RING(P18, FKM), KH-5000 1

16 2038195 ANVIL, KH-5000 1

17 2412445 O-RING(B), PHD-40M (D2.65*14.2) 1

18 2412903 ANVIL RING, PHD-40M 1

19 2031309 DAMPER WASHER, KH-5000M 1

20 2070530 DAMPER(B), KH-50H 1

21 2036602 CATCHER, KH-50H 1

22 2036018 STRIKER, KH-5000 1

23 2412426 O-RING(F)(D3.5*23.5,FKM), KH-50H (D3.5*23.5, FKM) 2

24 2412365 O-RING(A)(D2*32, Class 1- A), KH-42H (D2*32, Class 1- A) 1

25 2031013 CYLINDER(R1), KH-50H 1

26 2042018 CYLINDER CASE, KH-5000 1

27 2400912 HEX SOC HD B & SW(SCM4, M6*30,COAT) (SCM4,M6*30, COAT) 4

28 2412429 O-RING(D)(D2*52, NBR), KH-50H (D2*52, NBR) 1

29 2048085 SLEEVE, KH-50H 1

30 2064257 RING SPRING, KH-50H 1

31 2112709 PISTON, KH-5000 1

32 2412427 O-RING(E)(D2*22,NBR), KH-50H (D2*22, NBR) 1

33 2033811 PISTON PIN, KH-50H 1

34 2131385 CONNECTING ROD(R1), KH-50H 1

35 2074111 JACKET, KH-50M 1

36 2155053 GREASE COVER, KH-5000 1

37 2412310 O-RING(B, Red), PHD-3800 1

- 4 -

38 2021259 CRANK SHAFT,KH-5000 1

39 2412041 RETAINING RING(D40, For the hole) (D40, For the hole) 1

40 2417030 BALL BEARING(6203DDCMM) (6203DDCMM) 1

41 2041315 CRANK CASE, KH-5000 1

42 2413001 OIL SEAL(A)(D20.2*D35*4.5), PHD-3800 (D20.2*D35*4.5) 1

No Code No PART NAME SPEC Q,ty

43 2035001 SEAL BUSH(A), PHD-3800 1

44 2024356 GEAR, KH-5000 1

45 2417320 NEEDLE BEARING(M661) M661 1

46 2030347 BUSH, KH-5000 1

47 2043401 GEAR COVER, KH-5000 1

48 2417179 BALL BEARING(KBC, 6201DDHSAG) (KBC, 6201DDHSAG) 1

49 2051019 DUST PLATE(A), KH-50H 1

50 2412009 RETAINING RING(D14, C Type, A is) (D14, C Type, A is) 1

51 3004304 ARMATURE ASS'Y (LU, BMC), 220V, KH-5000 (220V) 1

52 2170206 DUST PLATE(B), KH-50H 1

53 2417156 BALL BEARING(NSK, 608ZZC2) (NSK, 608ZZC2) 1

54 2072332 RUBBER PACKING, PHD-40M 1

55 2130920 FAN GUIDE, KH-50H 1

56 3012259 STATOR ASS'Y,220V(DONGIL),KH-5000 (220V) 1

57 2405120 +PAN HD TAP S & PW(M5*55) (M5*55) 2

58 2141144 HOUSING, KH-50H 1

59 2400406 HEX SOC B & SW & PW(M6*35, COAT) (M6*35, COAT) 4

60 2100003 BRUSH CAP,D-13 2

61 2011113 CARBON BRUSH(AS,#45,118B10),KH-50H (AS, #45, 118B10) 1

62 2100108 BRUSH HOLDER,CS-7CA 2

63 2406012 HEX SOC SET SCREW(M5*8) (M5*8) 2

64 2011114 CARBON BRUSH(AS, #45, 118B10), KH-50H (AS, #45, 118B10) 1

65 2070532 BELLOWS(B), KH-50H 1

66 2155047 END COVER, KH-50H 1

67 2405140 +PAN HD TAP S&PW(M4*20, Black, Class 2) (M4*20, Black, Class 2) 2

68 2141513 CRANK CASE COVER(A), KH-50H 1

69 2065108 SPONGE CUSHION, KH-50H 1

70 2070531 BELLOWS(A), KH-50H 1

71 2070533 DAMPER(A), KH-50H 1

72 2411111 DAMPER SPRING, KH-50H 1

73 2403837 DAMPER NUT, KH-50H 1

74 3141037 HANDLE ASS'Y, KH-50H 1

75 2403025 HEX NUT(M6, Black) (M6, Black) 1

76 2008479 [SZ]TRIG.S/W(L/ON, 250V, 13A, JIABEN) (L/ON, 250V, 13A, JIABEN) 1

- 5 -

78 2402850 DAMPER BOLT, KH-50H 1

79 2402847 HINGE BOLT, KH-50H 1

80 2405131 +PAN HD TAP S & PW(M4*25, Black) (M4*25, Black) 3

81 2130504 CORD CLIP, PP-5B 1

82 2405105 +PAN HD TAP S & PW(M4*20) (M4*20) 2

83 2070333 CORD ARMOR(ID9), KH-50H (ID9) 1

84 3115680 CORD ASS'Y, 220(HO7RN-F, 2C*1.0*IEC66), KH-5000 (HO7RN-F2C*1.0, IEC66) 1

92 2060724 WASHER(B),PHD-40M 1

93 2058808 SEAL PACKING,KH-5000 1

94 325170

SIDE HANDLE ASS'Y,KH-50H 1

85 2073203 SIDE HANDLE,KH-42H 1

86 2400339 HEX HD BOLT(M8*140,Black) (M8*140,Black) 1

87 2110904 HOLDER,KH-50H 2

88 2038179 HOLDER BAND,KH-50H 1

89 2110851 CLAMPING NUT,KH-42H 1

90 2403031 HEX NUT(M8,Black) (M8,Black) 1

91 2110801 CLAMPING NUT CAP,KH-42H 1

- 6 -

Diagnoses and solutions to each type of problem

Symptoms

Problem

Location

Problem

Inspection Method Cause of Problem

How to deal with

problem What to do

Switch

■Check if

contact(break) is

established when

switched on/off.

◆Infiltration of foreign matter

◆Overuse e ceeding the durable

life

◆Damage by impact

◆Wear of contact point

◆Damaged terminal in the lead wire

connection section

▶Clean and remove

the

foreign matters

▶Replace the switch

☞Refer to

AS Manual

■Check for connection

state in the switch

◆Incorrect connection ▶Reconnect ☞Refer to

AS Manual

Cord

■Check for any break

in the cord

◆Breakage of wire near the cord

clip due to repetitive bending

during transit

◆Cord was nipped or damaged by

careless handling during

operation

▶Replace the cord ☞Refer to

AS Manual

Armature

■Check if the armature

coil has been broken

or burnt

◆Overload occurred during

stressful operation

◆Coil was damaged due to

infiltration of foreign matter

▶Replace the

armature

▶Clean & Replace

☞Refer to

AS Manual

Stator

■Check if the stator

coil has been broken

or burnt

◆Overload occurred during

stressful operation

◆Coil was damaged due to

infiltration of foreign matter

▶Replace the stator

▶Clean & Replace

☞Refer to

AS Manual

Carbon

brush

■Check if the carbon

brush makes contact

with armature

commutator

◆Carbon worn off in e cess of the

limit

◆Effective contact is not made in

the armature commutator due to

infiltration of foreign matter into

brush holder

▶Replace the

carbon brush

▶Clean & Replace

☞Refer to

AS Manual

Brush

holder

■Check the mounting

state of the brush

holder

◆Damaged brush holder due to

incorrect assembling

◆Brush holder fell off

▶Replace the brush

holder

☞Refer to AS

Manual

Armature

■Check the teeth of A/R

■Check for any damage

in armature fan

◆Wear of the teeth due to overuse

e ceeding durable life

◆Occurrence of damage of fan

during repair works

▶Replace the

armature

☞Refer to

AS Manual

Bearing

■Check for wear or

damage of bearing

◆Wear due to aging of bearing

◆Slip due to wear of bearing

mounting section

◆Incorrect distance of pressed

insertion part of the bearing

▶Replace the

bearing

▶Replace the

incorrect part

☞Refer to

AS Manual

Gear

■Check for wear or

damage of gear &

teeth

■Abnormal noise is

generated

■Check the state of

pushed-in gear

◆Wear and damage due to overuse

in e cess of durable life

◆Defective teeth in teeth section

◆Incorrect insertion of the gear

◆Worn off gear due to lack of

lubricating Grease

▶Replace the gear

▶Correct the

pushed-in state

▶Grease supplying

☞Refer to

AS Manual

Rubber

packing

■Check the rubber

packing to see if it is

missing or damaged

◆Generation of noise/vibration from

the shaky armature

■Assemble the

rubber packing

☞Refer to

AS Manual

- 7 -

No operaion pos

sible Vibraion/Nois

Bad

flame

Carbon

brush

■Check for correctness

of brush holder

assembly mounting

■Check for wear or

damage of the carbon

brush

◆Brush holder is unstable (shaky)

◆Overuse e ceeding the wear limit

◆Generation of flame due to use of

incorrect part

▶Replace the brush

holder

▶Replace the

armature

▶Replace the

carbon brush,

☞Refer to

AS Manual

Symptoms

Problem

Location

Problem

Inspection Method Cause of Problem How to deal with

problem What to do

Carbon

brush

■Check for correctness

of brush holder

assembly mounting

■Check for wear or

damage of the carbon

brush

◆Brush holder is unstable (shaky)

◆Overuse e ceeding the wear limit

◆Generation of flame due to use of

incorrect part

▶Replace the brush

holder

▶Replace the

armature

▶Replace the

carbon brush,

☞Refer to

AS Manual

Vibration

■Check for damage in

the bearing

■Check for wear in the

gear

◆Damage in bearing due to

overuse e ceeding durable life

◆Wear of gear due to overuse

e ceeding durable life

▶Replace the

bearing

▶Replace the gear

☞Refer to

AS Manual

Armature

■Check for scratch on

the surface of the

commutator

■Check for wear of the

surface of the

commutator

■Check for break or

burn out of the

armature coil

◆Scratch in the commutator due to

wear of carbon brush

◆Wear of commutator due to

overuse e ceeding durable life

◆Damaged coil or broken insulating

paper due to infiltrated foreign

matter (powder dust)

▶Replace the A/R ☞Refer to

AS Manual

Stator

■Check for damage in

insulating paper of

the stator coil

■Check for break or

burn out in the stator

coil

◆Damaged coil or broken insulating

paper due to infiltrated foreign

matter (powder dust)

▶Replace the stator ☞Refer to

AS Manual

Rubber

packing

■Check for missing the

rubber packing

◆Generation of sparks due to shaky

armature

■Assemble rubber

packing

☞Refer to

AS Manual

Incorrect

part

(painting

part)

■Check for any dent or

damage in the gear

cover/cylinder

case/crankcase

◆Material is defective

◆When the gear is disassembled or

assembled

◆Deformed shape

▶Replace the

incorrect part

☞Refer to

AS Manual

Injection

molding

■Check for any

damage in the

housing and the

handle assembly

■Check for any

damage in the end

cover

◆Inappropriate handling by the user

◆A crack was created during

forming

▶Replace the

housing,

handle

assembly

▶Replace the end

cover

☞Refer to

AS Manual

Armature/

Stator

■Check for

interference of the

armature or the stator

◆Incorrect fastening of the stator

fi ing bolt

◆Wear and damage in the bearing

▶Correct or replace ☞Refer to

AS Manual

Bearing

■Check for damage or

wear of the bearing

◆Use of incorrect bearing fi ture

◆Missing bearing assembly part

◆Wear or damage due to overuse

of bearing section e ceeding

durable lift

▶Replace the

bearing

☞Refer to

AS Manual

Grease

■Check the injected

amount of

grease(35g)

◆Generation of heat by friction due

to insufficient grease (piston,

striker)

▶Grease supplying ☞Refer to

AS Manual

Incorrect

part

■Check the wear state

at the mounting

section of the gear

(Crank case)

◆Wear of pressed insertion part of

the bearing due to overuse

e ceeding durable life

▶Replace the

incorrect part

☞Refer to

AS Manual

- 8 -

Bad

fame

Damag

Overheain

■Check if the gear

rotates unengaged

◆Dimensions of the part are

incorrect (e.g. distance between

a is)

◆Foreign matter or burr caught in

between

▶Replace the part

▶Remove the

foreign matter or

burr

☞Refer to

AS Manual

Others

■Check the voltage of

the power source (V)

◆Increased RPM of the

motor due to the use of

e cessively high voltage

▶Use appropriate

voltage

☞Refer to the

user manual

How to deal with each type of defective impact (KH-5000M)

Symptoms

Problem

Location of

Problem Inspection Method Cause of Problem

How to deal with

problem What to do

Damaged

parts

■Check for damage in

the piston

■Check for damage in

the connecting rod

◆Overuse in e cess of

durable life

◆Incorrect assembling

◆Sticking occurs due to lack

of lubricating oil

▶Replace the piston

▶Replace the

connecting rod

▶Grease supplying

☞Refer to

AS Manual

■Damage in the

crankshaft

◆Overuse in e cess of

durable life

▶Replace the

crankshaft

☞Refer to

AS Manual

■Check for wear or

damage of anvil

◆Overuse in e cess of

durable life

◆Lack of lubricating oil

▶Replace the anvil

assembly

☞Refer to

AS Manual

RPM

abnormal

■Check for the RPM ◆Control of motor RPM is

not possible due to

incorrect assembling of the

motor

▶Replace the motor ☞Refer to the

product

nameplate and

user manual

O-ring

■Check for missing

Oring

◆Incorrect assembling ▶Assemble the

piston, striker

oring

☞Refer to

AS Manual

Incorrect

assembling

■Check the assembled

direction of the damper

washer

◆Assemble the damper

washers in the opposite

directions

▶Reassemble the

damper washer

☞Refer to

AS Manual

■Check the assembled

direction of the striker

◆Assemble in the opposite

direction of the striker

▶Reassemble the

striker

☞Refer to

AS Manual

Power

supply

■Check the voltage of

the power source

◆Decreased SPM due to

use of incorrect voltage

◆Dropped voltage due to

e cessive use of lead wire

▶Use correct voltage ☞Refer to the

product

nameplate and

user manual

Bit

■Check the wear of bit ◆Dislocation from its original

position due to wear of the

contact surface of the anvil

▶Replace the bit

☞Refer to

User Manual

O-ring

■Check for wear or

damage of O-ring

◆Wear of the O-ring due to

overuse

◆Incorrect assembling

▶Replace the

piston, striker

oring

☞Refer to

AS Manual

Motor

Carbon

brush

■Check the Decreased

SPM

◆Decreased SPM due to

burned out motor

◆Decreased SPM due to

assembling with incorrect

motor

◆Defective contact of

commutator due to worn

carbon

▶Replace the motor

▶Replace the

carbon

☞Refer to the

product

nameplate and

user manual

Incorrect

part

■Check if the gear

rotates unengaged

◆Dimensions of the part are

incorrect (e.g. distance

between a is)

◆Foreign matter or burr

caught in between

▶Replace the part

▶Remove the

foreign matter or

burr

☞Refer to

AS Manual

Disassembly/

Assembly No. 01 Disassembly/

Assembly Name Clean and replace the carbon brush

- 9 -

Sriking

doe

s no occur

Weak

srengh

NO. Disassembly order and method Remark

★Replace the carbon brush

☞ Pull out the two #67 screws (M4*20) by turning them to the left with a

(+) screwdriver and detach the #66 end cover.

☞ Pull out the two #60 brush caps by turning them to the left with a (-)

screwdriver and detach the carbon brush. (Do the same for the

opposite side)

☞ Insert #64 carbon brush (general) and #61 carbon brush (auto stop)

and assemble #60 brush cap.

★Clean

☞ (Proceed with disassembling procedures 1 and 2.) Blow the air through

air outlet between #58 housing and #47 gear cover to remove foreign

matters and dust.

☞ Blow the air to the carbon brush holder to remove foreign matters and

dust. (Do the same for the opposite side)

[Note 1]

♠ General carbon brush in

the number 45 stamped.

Auto stop carbon brush

in the number 46

stamped.

[Caution 1]

♠ Be careful not to destroy

the screw thread when

reassembling the #66

screw (M4*20)

[Caution 2]

♠ When reassembling, be

careful not to damage

#60 brush cap.

Disassembly /

Assembly No. 02 Disassembly/

Assembly Name

How to replace the

cord/handle/switch

- 10 -

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