Kango K 350 Setup guide

1
PAGE
Repair Instructions
K 350
Important! Before carrying out any repairs, the hammer should be checked for electrical safety and for mechanical
performance. For electrical safety the hammer should be placed on a non-conductive surface which is
either of a wooden construction (with the mains supply disconnected) which contains no metal parts or
a bench which is insulated by a rubber mat. The hammer should then be checked by high voltage flash
testing. On completion of dismantling procedure all electrical components should then be checked for
electrical safety. The hammer should ONLY be checked for hammer performance if the unit passes the
electrical safety test.
Disassembly
Removing the
carbon brushes 1Remove the attaching bolts (85) and the protective cap (9).
2Disconnect the wire (B) and pull the brush
holder (15) from the housing.
3Movethespring(A)aside(seeillustration)
and remove the carbon brushes (88).
Disconnect the carbon brush cables.
☞From date of construction 03/99, the
carbon brush connection is located di-
rectly on the field. 88
B
A
15
88 9
85
➞ 03/99
03/99 ➞
1

2
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Repair Instructions
K 350
Dismantling the
SDS-Plus-Recep-
tion
1Remove the rubber cover (87).
2Remove the spacer (60).
3Remove the sliding sleeve (87) and the re-
taining ring (64).
4Depress the support plate (63) and press
out the ball (62) with the aid of a screw-
driver or remove it with a magnet.
5Remove the support plate (63) and the
pressure spring (61).
Removing the
gear housing 1Removing the switch lever (87): Switch the lever to the hammer only posi-
tion and break it off with aid of pliers (the
lever is being destroyed).
Note: Should this not be possible mount
theswitch ina viceand breakit offby rock-
ing the machine. Remove any broken
parts from the machine.
2Remove the four housing bolts (85).
3Remove the gear housing.
Removing the
spindle 1Remove the two bolts (85).
2Remove the pin (44).
3Remove the offset gear (37) and the ring
gear (38).
4Remove the complete spindle sleeve (46)
from the cylinder.
Removing the
striker 1Position the spindle (46) vertically and briefly hit the plunger using a suitable
drift - the striker (39) comes free.
60
87 64 62 63 61
87
2
25
85
87
3
43
85 46 27
44 37 38
4
46
39
5

3
PAGE
Repair Instructions
K 350
Dismantling the
spindle
(removing the
outer parts)
1Removing the rear thrust bearing assem-
bly: Lever off the spiral clip (53) with a
screwdriver. Remove the thrust bearing
assembly in the following component
parts:
– washer (58)
– thrust bearing (52)
– two compensating washers (65)
– profile ring with damper O-ring (51)
2Remove the retaining plate (45) and the
slider (43).
3Removing the spindle gear (49):
Press the spindle gear (49) using a suita-
ble sleeve against the cup springs (47) -
the spring ring (50) is released and can be
removed with pliers. Remove the spindle
gear (49).
4Remove the stop washer (48) and the cup
springs.
Dismantling the
spindle (remov-
ing the inner
locking ring)
To remove the locking ring, service tool
4.931 5990 84 is needed (see illustration 7).
1Turn the locking ring (53) with aid of serv-
ice tool, such that one end projets the
service boring by approx. 2 mm.
2Put a screwdriver through the service bor-
ing and place it under the locking ring (53).
3Move the screwdriver to and fro and at the
same time turn the locking ring with aid of
the service tool in direction of arrow. Turn
the locking ring until it is completely lev-
ered off.
4Press the locking ring from the spindle.
47 48 4950 43 45
53
50
47
49
58
5152
65
6
53
B
A
53
7

4
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Repair Instructions
K 350
Dismantling
the spindle
(inner parts)
1Press the following parts from the
spindle (46):
– backing flange (56)
– sleeve (54)
– snap die (57)
– sleeve (59)
2Remove the O-rings (87).
Removing the
back gear shaft
and the cylinder
1Pullout thebearinghousing(70)orloosen
the bearing housing by hitting the gear
housing lightly with a plastic hammer.
2Remove the tumble drive (35) and the cyl-
inder (40).
3Press out the bolt (42) by hand and re-
move the two disks (41) (older machines:
guide ring (see box).
4Remove the needle bearing (87) with aid
of an interior extractor. In case of older
machines, remove the 13 rollers (90) from
the back gear shaft.
Dismantling the
back gear shaft 1Remove the “O” ring (87).
2Remove the disk and the thrust
bearing (30).
3Press off the reduction gear (36).
4Remove the remaining parts from the re-
duction gear shaft (29):
– tumble drive (35)
– disk (34)
– coupling sleeve (33)
– spring (32)
– disk (31)
54
59
46 87 57
56
87
09/97
8
08/9608/96
09/97
70
42
41
40
35
87(90)
9
29
31 32 3334 35 36 87
30
10

5
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Repair Instructions
K 350
Removing the
angle drive 1Remove the locking washer (67).
2Remove the shaft (82) together with the
discs (72 & 73) and the ring (71). (If nec-
essaryby hitting the gear box lightly with a
plastic hammer).
Note: Depending on the tolerance of the
bearing,thetoolcanbeequippedwiththetwo
or three discs (72 &73). Note the numbers of
the discs and use the same number when re-
assembling.
Removing the
motor cover 1Remove the four bolts (85) and remove the protective cap (8).
Dismantling
the handle 1Remove the pin (4).
2Disconnect the field supply cables (18,19)
from the contacts and pull them from the
field housing.
3Removetheattachingscrews(85)andthe
handle cover (86).
4Remove the silicone buffer (12).
5Remove the locking ring (6) and the wash-
er (5).
6Remove the AVS-rubber (87).
7Remove the handle (86).
8Unscrew and remove the handle bolt (68).
72
67
82 71
66
73
11
8
85
12
85
86 87 56
68
41
8
27 12
86
18,19
13

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Repair Instructions
K 350
Removing the
electrical parts 1Unscrew the cable collar (17).
2Remove following parts:
– switch (22/23)
– capacitor (24)
– cable (1)
– wire (18/19)
Removing
the motor 1Remove the bolts (85) and pull out the motor (if necessary, hit the motor hous-
ing (27) lightly with a plastic hammer).
22/23
85
86
1
17
18
19
14
85
27
85
15

7
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Repair Instructions
K 350
Removing and
dismantling the
armature
1Remove the seal ring (21).
2Lever off the bearing cover (20) and re-
move the silicone buffers (12).
3Pull out the entire armature (74).
4Press off the gear wheel (82).
5Remove the spacer (81), sleeve (80) and
the bearing (77).
Removing
the field 1Remove the air deflector ring (11) and the silicone buffers (12).
2Pull the field coil (10) from the casing (7)
and remove the centering ledges (16).
20 12
82
81
80
77
74
21
16
16
7
12
11
10
17

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Repair Instructions
K 350
Maintenance
General For best performance hammers should be serviced at regular intervals, any indication that the hammer
is not performing as specified should be investigated to prevent any adverse damage occurring.
ALL SEALS, GASKETS, GREASE OR OTHER PARTS DEEMED NECESSARY FOR SERVICING
ARE IN THE SERVICE KIT.
ALL NEEDLE ROLLER BEARINGS SHOULD BE PRESSED WITH THE ROUNDED EDGE ENTER-
ING THE BORE FIRST, AND THE PRESS TOOL PRESSING AGAINST THE FLAT SURFACE OF
THE BEARING.
Cleaning All mechanical parts with the exception of any sealed bearings should be cleaned in a suitable cleaning
fluid. Electrical parts should be cleaned by the use of compressed air.
PRECAUTIONS MUST BE TAKEN FOR PERSONAL SAFETY THE USE OF EYE PROTECTION
AND GLOVES IS RECOMMENDED.
Check for wear Check the disassembled parts for wear (visual inspection) and replace worn parts.
Lubrication At service and repair intervals the lubrication should be carried out as shown in the diagram below.
All parts in the service kit should be fitted. The total amount of grease for the 350 is 30 grms (1 tube)
(9170 3043 23, blue). Lubrication of the hammer is as shown on the grease chart.
ALL SCREWS SHOULD BE REFITTED WITH LOCKTITE 222 OR SIMILAR.
D
A
B
E
E
E
E
E
G
H
I
K
LM
N
O
P
Q
F
F
C
S
T
U
1g
1g
1g
1g
1g
2g
8g
4g
4g
1g
1g
1g
1g
4g
0.5g
0.5g
0.5g
0.5g
5g
2g
2g

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Repair Instructions
K 350
ELECTRICAL TESTING
Electrical tests Before assembly all electrical parts MUST be checked for safety, and that they conform to specification.
Testing the
Armature
(Flash Testing)
Supplementary Insulation
Apply 1250 volts rising to 2500 volts A.C. between laminations and spindle (A). See dia-
gram.
Basic Insulation
Apply 750 volts rising to 1500 volts A.C. between commutator segments and lamina-
tions (B). See diagram.
A Armature shaft to lamination pack 2500 volts
B Lamination pack to commutator 1500 volts
C Armature shaft to commutator 4000 volts
D Commutator to commutator bush 1500 volts
E Commutator bush to shaft 2500 volts
ELECTRICAL PERFORMANCE TEST READINGS
ARMATURES
MODEL 110V/120V 220V/230V/240V
350 0.927Ω3.297Ω
FIELD COILS
110V/120V 220V/230V 240V
350 0.121Ω0.429Ω0.499Ω
PERFORMANCE
110V/120V 220V/230V 240V
350 17 amps 10 amps 9 amps
Note: On all test readings + or - 5% of figures shown is acceptable.

10
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Repair Instructions
K 350
Assembly
Mounting
the field 1Fit the centering ledges (16) to the field coil (10).
Caution: Care must be taken to ensure
the correct positioning of the centering
ledges (16) (see illustration).
2Insert the field coil (10) into the field hous-
ing (7) (lightly hit the field housing with a
plastic hammer).
3Insert the silicone buffers (12) into the air
deflector ring (11).
4Den Luftleitring (11) einsetzen.
Caution: Care must be taken to ensure
the correct positioning of the air deflector
ring (see illustration).
Assembling and
mounting the
armature
1Pushthe bearing(77),thespacer(81)and
the seal ring (80) seal nearest to the com-
mutatorontothe armature shaftand press
on the gear wheel (82).
2Insert the complete armature (74) into the
case (7).
3Push the silicone buffers (12) onto the
case (7).
4Fit the bearing cover (20) in the case (7).
5Push the seal ring (21) onto the field hous-
ing.
Mounting
the motor 1Insert the motor (7) into the motor hous- ing (27).
Caution: Care must be taken to ensure
the correct positioning, the lug (A) must fit
in the recess on the motor housing (27).
2Fasten the motor with bolts (85) (2,5Nm).
16
7
12
11
10
1
20 12 82
81
80
77
74
21
7
2
85
27
7A
85
3

11
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Repair Instructions
K 350
Assembling the
electrical parts 1Connect all cables to the switch (see illus- tration and wiring diagram).
2Push the field cables (18,19) through the
handle (see illustration).
3Insert the switch (22), the capacitor (24).
Note: Install the field supply cables (A)
below the mains cable near the cable col-
lar (17).
4Fasten the cable collar (17) with
screws (85) (1Nm).
Mounting the
handle 1Screw (10 Nm) the handle bolt (68) with screw locking device onto the motor hous-
ing (27).
2Push the handle (86) over the bolt (68)
and fix the AVS-rubber (87) with the wash-
er (5) and locking ring (6).
3Insert the silicone buffer (87) into the han-
dle cover (86).
4Fasten the handle cover (86) with the
bolts (85) (1,2 Nm).
5Push the field supply cables (18,19)
through the channels of the field housing
(see illustration) and connect them with
the field (diagonally).
6Fasten the handle with the grooved dowel
pin (4).
Press in the grooved dowel pin (4) or
knock it in with a rubber hammer.
Mounting the
motor cover 1Fit the protective cap (8) and fasten it with the bolts (85) (1,8 Nm).
☞Take care that the protective cap (87)
is firmly stuck in the motor cover (8).
22
85
17
18,19
12
C2 C1
Black
Yellow
Blue
Blue
+ -
A1
A2
E2
E1
3
4
85 86
87 87 56
4
18,19
27
86
68
5
87
8
85
6

12
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Repair Instructions
K 350
Assembling the
angle drive 1Insert the support ring (71).
2Grease the shaft (82) and insert into the
gear box (27) by turning it slightly.
3Insert the disks (72 &73).
Note: Depending on the tolerance of the
bearing, two or three disks (72 &73) are
needed. For assembly, use the same
amount of disks as removed.
4Insert the locking washer (67) such that
the lugs face the bearing (see illustration).
Mounting the
spindle bearing 1Press the sintered bearing (69) into the
bearing housing (70).
2Insert the bearing housing (70) into the
gear box (27).
Note: Do not press in the bearing hous-
ing (70) completely for easier mounting of
the back shaft (29) and the cylinder (40).
Caution: Care must be taken to ensure
the correct positioning of the bearing
housing (70).
Assembling the
back gear shaft 1Fit the following parts onto the back of re- duction gear shaft (29) in the following or-
der:
– disk (31)
– spring (32)
– coupling sleeve (33)
– disk (34)
– tumble drive (35)
2Press on the reduction gear (36) with
0.05 mm to the tumble drive.
Caution: the smooth surface must face
the tumble drive (35).
3Lightly grease the thrust bearing (30) and
insert it into the reduction gear (36).
4Fit the disk (30) and check the distance:
– ifthedistanceismorethan100.5mm,do
not fit the disk (30).
– if the distance is less than 100.5mm fit
another disk (30) and check the dis-
tance again.
5Push on the O-ring (87).
67 66
82 71
27
72 73
7
69 70
27
8
X0,5 mm
35 36 30
29
31 323334 35 36 87
30
9

13
PAGE
Repair Instructions
K 350
Mounting the
back gear shaft
and the cylinder
1Insert the two disks (42) and the bolt (41)
into the cylinder (40).
☞Replace the hoop (43) with two wash-
ers (42).
2Insert the rolls (87)/(90) into the back gear
shaft one after the other and fix it with
grease.
☞Mounttherolls(87)completelywiththe
cage (from date of manufacture 09/97).
3The back gear (35) can only be inserted
as follows:
– Put together the cylinder and the back
gear for adjustment before mounting
them.
– Turn the tumble drive to the lowest posi-
tion and leave it there
– Insert the cylinder into the end shield
– Insert the tumble drive into the mounted
cylinder.
4Grease the striker (39) and insert it into
the cylinder.
Assembling the
spindle
(mounting the
inner parts)
1Push the O-rings (87) into the sleeve.
2Fitthesleeve(59),theO-ring(87),andthe
sleeve (54) to the snap die (57) and insert
them into the spindle (46).
3Insert the disk (55) into the spindle upto
the O-ring.
4Press the locking washer (53) with a suit-
able sleeve into the spindle (46) until the
locking washer (53) engages.
Caution: Check the service boring (visual
check) to make sure the locking ring (53)
has engaged.
08/9608/96
09/97
70
42
41
40
39
35
43
87(90)
10
54
59
46 87 57
55
87
53
09/97
11

14
PAGE
Repair Instructions
K 350
Assembling the
spindle
(mounting the
outer parts)
1Mount the cup springs (47) (see illustra-
tion).
2Mount the clutch (the stop washer (48)
with indentations against the toothing of
the spindle gear (49)).
3Fit the spring ring (50) and press it
on (against the pressure of the cup
springs (47)).
4Mount the slides (43) and the retaining
plate (45).
5Mounting the rear thrust bearing assem-
bly:
– profile ring with damper O-ring (51)
– two compensating washers (65)
– thrust bearing (52)
– washer (58)
6Secure the rear thrust bearing assembly
with the locking washer (53).
Mounting
the spindle 1Fasten the spindle (46) to the motor hous- ing (27) with the two screws (85) (6 Nm,
for additional security use Loctite 222 or
Omnifit.).
2Pushthe ring gear (38) overthe backgear
shaft (29) and let it engage in the locking
slide (43).
3Push the planetary gear (37) onto the
back gear shaft (29) and fit them into the
ring gear (38).
4Pushthe straight pin (44) through the lock-
ing slide (43) and insert it into the motor
housing (27).
Mounting the
gear housing 1Insert a service tool (A) into the gear (25) (the sleeve protects the corrugated seal
ring inside the gear (25) from damage dur-
ing assembly).
2Fit the gasket (87) to the gear
housing (25).
3Fasten the gear box (25) to the motor
housing (27) and fix it with bolts (85)
(2,5+0,5Nm).
4Fit the switch lever (87) (mount it in the
“hammer” position, the pin must grasp the
elongated hole of the locking slide).
53
45
43
50
49
48
47
51 65 58
52
12
43
85 46 27
44 37 38
29
13
A
25 87 27
87
85
14

15
PAGE
Repair Instructions
K 350
Mounting the
SDS-plus
Reception
1Insert the spring (61) and the support
plate (63).
2Depress the support plate (63) and insert
the ball (62).
3Fit the retaining ring (64) and the sliding
sleeve (87).
4Fit the spacer (60).
5Push down the sliding sleeve (87) and fit
the rubber (A).
Mounting the
carbon brushes 1Insert the brush holder (15) into the hous- ing and connect the cable to the field.
2Insert the carbon brush (88) into the brush
holder (15) and put the spring (A) onto the
carbon brush. Fit the flat plug.
3Fasten the service cover (9) with the
bolts (85).
☞From date of construction 03/99, the
carbon brush connection is located di-
rectly on the field.
60
87 64 62 63 61
A
15
88 A
1588 985
03/99➞
➞03/99
16

16
PAGE
Repair Instructions
K 350
WARNING After completed assembly, the machine should be submitted to a flashover test with 4000 volts.
It is advisable to run the machine with half the rated voltage to make sure that the brushes are
inserted correctly. After 10 minutes the machine should be run with full rated voltage. The per-
formance test values should be compared with these values.
With the breaker completely assembled and with the switch “ON” apply 2000 volts initially and increase
rapidlyto 4000volts betweenthe maincasting andone ofthe pinsof theplug onthe powersupply cord.
Apply test to both live and neutral pins.
WARNING Do not touch the other pin during this test since it is live.
The full voltage of 4000 volts should be maintained without breakdown or flashover for a few seconds.
If the armature has been tested, remove the carbon brushes before carrying out the test, (thus avoiding
over-stressing the armature insulation system.) As a result, a further over-stressing of the armature in-
sulation is avoided. In this case the test voltage must be carried out between the conductive cast part
and each pin one after the other.
WARNING If the machine is not switched on, faults could be not found and the user could suffer an elec-
tric shock. Make sure the switch is in the “On” position.
Fault finding
With the aid of the Fault Finding chart (below) the source of any malfunction may be quick-
ly identified and repaired.
REMEDY FAULT
AND RETEST
MOTOR
REVOLVES?
MACHINE
HAMMERS?
MACHINE
IDLES?
SUPPLY
OK?
PLUG FUSE
OK?
BRUSHES
OK?
CORD
OK?
SWITCH
OK?
ARMATURE FIELD INTERNAL
WIRING
SERVICE
MECHANISM
MODULE
WAS MOTOR
BURNT OUT?
MACHINE
OK
YES
NO NO
YES
YES YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO