Kango K 200 Setup guide

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Repair Instructions
K 200
Special Tools
Required
■ Mandril (diameter 9.5 mm), approx. 100 mm long.
■ Assembly support in which the tool can be fixed vertically.
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
S
Dismantling the
chuck
1
Lever off the spring ring (4) with aid of a
screwdriver.
2
Remove the set sleeve (3) with spacer (2).
3
Remove the jumper ring (1).
Dismantling the
gear box
1
Insert the machine into the assembly sup-
port and remove the four screws (5).
2 Lever off the switch lever (2) with aid of a
screwdriver.
3
Remove the gear box (4).
4
Remove the pin (7), the gear switch lever
(6), and the O-ring (3) together with the
discs.
5
Remove the gear wheel (1).
6
Remove the spindle sleeve (8).
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Repair Instructions
K 200
Dismantling the
reduction gear
1
Remove the axial needle bearing (4).
2 Take out the complete reduction gear,
then remove the reduction gear shaft (8).
3
Remove the needle bearing (2) and the
sealing ring (1).
4
Remove the sleeve (7), the pin (6), and
the bearing (3).
5
Remove the gasket (5).
Dismantling the
cylinder
1
1 Remove the cylinder (3) together with
the percussion body (4). Pull the percus-
sion body (4) from the cylinder (3).
2
Press the snap die (2) from the drill spin-
dle (5) with aid of a mandril. The spring
ring, the washer, and the rubber ring are
being destroyed.
3
Remove the sealing ring (6).
4
Remove the needle bearing (1).
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Repair Instructions
K 200
Dismantling the
handle shells
1
Unscrew and remove the service cover
(2).
2
Loosen the screws of the cable clip (5), re-
move it and lay bare the power supply
lead.
3
Loosen the connectors (4).
4
Unscrew and remove the housing (3).
Dismantling the
motor
1
Lever off the brush holder insulation (1)
andthebrushholders(3)togetherwiththe
carbon brushes (2).
2
Dismantle the switch.
3 Branch off the cords.
4
Removethearmature(4)togetherwiththe
field (5) from the housing.
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Repair Instructions
K 200
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
maintenance set must be exchanged. Use the respective maintenance set provided for each machine.
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
Cover with grease (10 g Tivela)
B
Cover with grease (20 g Darina)
Torques Screws in plastic 2.0 Nm
Screws in metal 3.0 Nm
B A
A A
A A
A
AAA A

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Repair Instructions
K 200
Assembly
Mounting the ar-
mature
1
Insert the armature (4) together with the
field (5) into the housing.
2
Mount the switch.
3
Insert the brush holder insulations (1) and
thebrush holders(3)together withthecar-
bon brushes (2) into the housing.
Assembling the
housing
1
Fit the housing (3) and fasten it with
screws. Take care that no cables are
squeezed or jammed.
2
Fixthe powersupplylead withtheconnec-
tors (4) and fasten the cable clip (5) with
screws.
3
Screw down (1) the service cover (2).
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Repair Instructions
K 200
Mounting the
cylinder
1
Mount the needle bearing (1).
2 Insert the sealing ring (6).
3
Insert the snap die (2), the rubber ring, the
washer,the spring ring, and the drill spin-
dle (5).
4
Insert the cylinder (3) as shown in illustra-
tion. Insert the percussion body (4) into
the cylinder (3).
Assembling the
reduction gear
1
Mount the bearing (3) and the gasket (5).
2 Insert the pin (6) and the sleeve (7).
3
Mount the sealing ring (1) and the needle
bearing (2).
☞
Press the reduction gear wheel (9)
onto the wobble gear drive. The end
play must be 0.05 + 0.03 mm.
4
Mount the reduction gear complete with
thereductiongear shaft (8).Insertthe disc
springs opposite each other (see illustra-
tion).
5
Mount the axial needle bearing (4).
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Repair Instructions
K 200
Mounting the
gear box
1
Insert the spindle sleeve (8) into the gear
box.
2
Fit the gear wheel (1).
3
Insert the O-ring (3) together with the
discs. Mount the gear switch lever (6) and
the pin (7).
4
Place the complete gear box (4) onto the
motor housing.
5 Insert new switch lever (2) into the gear
box.
6
Fit the gear box (4) to the motor housing
and fasten with the four screws (5).
Mounting the
chuck
1
Fit the jumper ring (1).
2
Insert the set sleeve (3) with spacer (2).
3 Insert the spring ring (4).
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).
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