Kango 2500 Installation and operating manual

4
Service and Repair Manual
Model 2500V
ServiceTools
TORQUE SETTINGS
1234
5
12
20
13
14
23 24
30
25 26 27 28
31 32
15 16 17 18 19
22
21
29
6
810
11
9
7
ITEM PART NO. DESCRIPTION
1 9170 0739 60 10mm HEX. SOCKET, 3/8" SQ. DRIVE.
2 9170 0731 90 7/8" BSF HEX. SOCKET
9170 0735 50 24mm HEX. SOCK ET, 1/2" SQ. DRIVE.
9170 0738 90 17mm HEX. SOCKET, 1/2" SQ. DRIVE.
3 9170 0739 40 IN-HEX BIT, 6mm AF, 1/2" SQ. DRIVE
9170 0739 50 IN-HEX BIT, 10mm AF, 1/2" SQ. DRIVE
4 9170 0230 60 EXTENSION BAR, 10" LONG, 1/2" SQ. DRIVE
9170 0732 50 EXTENSION BAR, 5" LONG, 1/2" SQ. DRIVE
5 9170 0732 80 TORQUE WRENCH 1/4" DRIVE
6 9170 0235 50 TORQUE WRENCH 25-135Nm (1/2" SQ. DRIVE)
7 9170 0732 30 SCREWDRIVER BIT
8 9170 0734 70 CONVERTER, 1/4" SQ. SKT. TO 3/8" SQ. PLUG
9 9170 0732 40 SCREWDRIVER BIT ASSEMBLY
10 9170 0737 70 POZIDRIVE NO.2 REPLACEMENT BIT
10 9170 0737 80 POZIDRIVE NO.3 REPLACEMENT BIT
11 9170 0732 90 SCREWDRIVER BIT POZIDRIVE NO.2
11 9170 0732 00 SCREWDRIVER BIT POZIDRIVE NO.3
12 9170 0236 80 GREASE GUN
13 9170 0731 30 SPLIT SLEEVE (ARMATURE)
14 9170 3329 90 DISMANTLING LAYSHAFT BEARINGS
15 9170 3329 80 ASSEMBLY LAYSHAFT BEARINGS
ITEM PART NO. DESCRIPTION
16 9170 0737 10 ASSEMBLY CRANKSHAFT NEEDLE BEARING
17 9170 0230 30 ASSEMBLY ARMATURE SEAL ASSY
18 9170 0738 00 ASSEMBLY CRANKSHAFT INNER BEARING
19 9170 0738 10 ASSEMBLY PRESS TOOL(C/SHAFT SUPPORT)
20 9170 0733 30 STANDARD ALLEN KEY, 6mm AF
9170 0733 40 STANDARD ALLEN KEY, 10mm AF
9170 0733 50 STANDARD ALLEN KEY, 5mm AF
21 9170 0236 90 CIRCLIP PLIERS
22 9170 0738 20 ASSEMBLY C/SHAFT BEARING INNER RING
23 9170 0736 70 ASSEMBLY BEARING HOLDER BEARING
24 9170 0738 30 ASSEMBLY/DISMANTLING CONNECTING ROD
25 9170 0738 40 ASSEMBLY PRESS TOOL (LAYSHAFT)
26 9170 0738 50 MANDREL
27 9170 0737 00 ASSEMBLY/DISMANTLING TENSION ROD
28 9170 0734 40 SERVICE STAND (FOR 32mm AF NOSEPIECE)
9170 0739 10 SERVICE STAND (FOR 28mm AF NOSEPIECE)
29 9170 0738 60 ASSEMBLY/DISMANTLING (LAYSHAFT)
30 9170 0736 80 ASSEMBLY C/SHAFT LARGE BEARING
31 9170 0197 60 M4 X 16mm POZI-PAN SCREW (PK20)
32 9170 0739 00 PINION NUT
ITEM NO. PART NO. Nm lb.ft
101 9170 0510 60 40 30
105 9170 0510 70 4.5 3.5
110 9170 0510 50 25 20
113 9170 0691 70 3 2.25
121 9170 1975 00 1.25 1.0
124 9170 2797 50 1.25 1.0
205 9170 0198 70 1.25 1.0
212 9170 6908 00 3 2.25
214 9170 0519 20 1.75 1.25
216 9170 0502 40 40 30
218 9170 3305 60 6.0 4.5
219 9170 0511 70 40 30
ITEM NO. PART NO. Nm lb.ft
309 9170 0510 50 35 25
324 9170 0697 10 70 50
327 9170 0510 60 25 20
401 9170 0503 70 40 30
414 9170 0511 00 130 100
510 9170 3207 50 130 100

5
Service and Repair Manual
Model 2500V
1
2
3
4
5
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.
1. Remove the four cap screws (5) washers (4) and
cups (3). Lift off nosepiece (2).
2. Remove buffer (1) it may be necessary to lever the
buffer with a screwdriver to aid removal.
1. Remove the split pin and remove the castellated
nut (1) remove the dished and flat washer.
2. Remove bolt (4) together with the dished and flat
washer.
3. Press out the tension pin (5), see service tool list.
4. Remove the latch (2) plunger and spring (3).
DISMANTLING
Dismantling
the nosepiece
Removing
the nosepiece
1
2
3
4
5
Fig. 2
Fig. 1
1
5
43
2

6
Service and Repair Manual
Model 2500V
1. Remove the buffer housing (2) from the barrel and
push out the anvil (4).
2. Remove the recoil buffer (3) with a screwdriver.
3. With a screwdriver remove the anvil seal (5).
4. Remove the capscrews (7) and retaining rings and
lift off the barrel (1).
5. Pull the striker (8) off the piston (6).
1. Remove the O-rings (1) from piston (3) and push
out the gudgeon pin (2).
2. With a screwdriver remove the piston seals (4).
1. Remove the four cap screws (6) from the
handle (1) and remove the handle.
2. Remove the six capscrews (7) from the gear
case (4) and remove the cover.
3. Remove the four capscrews (8) from the switch
cover (5) and remove the cover.
4. Remove the four capscrews (9) from the switch
handle (3) and remove the switch handle (the
springs on the switch actuator will need to be
disconnected).
5. Remove the four pozi-screws (10) from the top
cover (2) and remove the top cover.
Dismantling the
barrel
Removing the
handles and
top cover
Removing the
piston
1
6
2
3
4
5
78
1
4
1
2
3
1
3
45
2
6
9
10
8
7
Fig. 3
Fig. 4
Fig. 5

7
Service and Repair Manual
Model 2500V
1. Remove the four pozi-screws from the switch cover
(7) and remove the cover.
2. Remove the switch seal (6) from the switch.
3. Pull the switch (5) from its location. Disconnect the
two motor leads and the two power leads. Remove
the two pozi-screws from the cord grip and remove
the power lead.
4. Remove the switch sleeve (8), switch box (4) and
remove the O-ring seal.
1. Remove the slot head screw (4) and brush cover (3).
2. Remove the pozi-screw (2) and dished washer (5)
from the brush holder gently pull out the brush (1).
3. Repeat the procedure for the brush on the opposite
side.
1. Pull off the layshaft gear (1), remove the thrust
bearing assembly (3) and thrust washer (14).
2. Press out the needle roller bearings (2) from the
layshaft gear. ( see service tool list).
3. Secure crankshaft (10) to prevent rotation, remove
the lock nut (5) disc spring washer (6) and lever off
the crankshaft gear (7) from square key (9), remove
square key (9).
4. Remove the three capscrews (11) from the
crankshaft housing (8) and lever the housing off the
crankshaft, (it may be necessary to gently tap the
threaded portion of the crankshaft with a nylon
hammer to loosen the assembly). Remove crankshaft
(10) and connecting rod assembly from main
casting.
5. Remove three capscrews (12) and remove the
layshaft carrier (4).
Removing the
switch
Removing the
brushes
Dismantling
the gear
assembly
132
4657
1
3
2
5
4
13
2
57
6
8
11
9
10
4
14
Fig. 6
Fig. 7
Fig. 8
12
8

8
Service and Repair Manual
Model 2500V
1. Remove the circlip (1) from the crankshaft housing
and press out the bearing (2), see service tool list.
2. Turn housing over and press out needle roller
bearing (3), see service tool list.
1. Lever out the seal assembly (3) and seal (5) with a
screwdriver.
2. Remove the circlip (1).
3. Press out the needle roller bearing (2), see service
tool list.
1. Clamp the crankshaft (1) in a vice with the big end
journal uppermost, unscrew the capscrew (4),
remove the bearing retainer (7) and thrust washer
(3), slide off the connecting rod (2), press out the big
end needle roller bearing (8) from the connecting
rod, remove the big end journal inner bearing (9),
(this may be done by carefully grinding a flat across
the bearing surface to weaken it, and is only
necessary if signs of wear are seen), and remove
second thrust washer (10).
2. Remove the circlip (5) and with a pin punch through
the two holes provided drive off the needle roller
bearing inner (6).
Dismantling
the crankshaft
Removing the
bearings from
the crankshaft
Dismantling
the layshaft
carrier
1
3
2
1
3
2
45
1
3
2
56
4
7
10 98
Fig. 9
Fig. 10
Fig. 11

9
Service and Repair Manual
Model 2500V
1. Remove the three screws (1) and washers (2) from
the bearing holder (4).
2. Remove the armature (3) and bearing holder
assembly from the motor housing.
3. Remove the spring anchor (5) and springs (6).
1. Unscrew the fan locking nut (1), flat washer (7)
and remove the fan (6), and spacer washer (8).
2. Pull the bearing housing (3) off the armature (9),
remove brush spring (10).
3. Remove the circlip (5) from bearing housing (3)
and press out the bearing (4).
4. Hold the armature firmly in the jaws of a vice,
precautions should be taken not to damage the
core of the armature, with the service tool, remove
the pinion (2) and spacer (11), see service tool
list. The service tool is held in position with a
screw provided. (Unscrew the pinion anti-clock-
wise).
1. Pull the field assembly (1) and brush holder hous-
ing (2) from the top housing, (if the assembly is
tight holding and knocking the top housing
lightly on a firm surface will assist in its re-
moval).
2. Release screws (3) from the retaining lock nuts
(4) to separate field coil (1) from the brush holder
housing (2).
Removing the
armature
Dismantling
the armature
Removing the
field assembly
4
3
2
5
1
65
4
10
9
2
3
11
8
1
7
1
23
5
4
Fig. 14
Fig. 13
Fig. 12
6

10
Service and Repair Manual
Model 2500V
General Hammers must be serviced at regular intervals, any indication that the equipment is not functioning as
specified, should be investigated to prevent any adverse damage occurring.
ALL SEALS, GASKETS, GREASE OR OTHER PARTS DEEMED NECESSARY FOR
MAINTENANCE ARE IN THE SERVICE KIT.
ALL NEEDLE ROLLER BEARINGS SHOULD BE PRESSED WITH THE ROUNDED
EDGE ENTERING THE BORE FIRST, AND THE INSERTION 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.
Inspection All mechanical and electrical parts should be inspected for wear and replaced as required.
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 2500 is 320 grms. Lubrication
of the hammer is as shown below on the grease chart.
ALL SCREWS SHOULD BE REFITTED WITH LOCTITE®222 OR SIMILAR
100gm
GREASE APPLICATION CODE
GREASING PROCEDURE
Liberally coat
Pack
Generously coat
Smear
50/60 gm 20gm
40gm
20gm

11
Service and Repair Manual
Model 2500V
ARMATURES
MODEL 110V 120V 220V 240V
2500V 0.156Ω0.156Ω0.482Ω0.482Ω
FIELD COILS
110V 120V 220V 240V
2500V 0.121Ω0.121Ω0.429Ω0.499Ω
PERFORMANCE
110V 120V 220V 240V
2500V 17 amps 16 amps 10 amps 9 amps
ELECTRICALTESTING
ELECTRICALPERFORMANCETEST READINGS
Electrical test Before assembly all electrical parts MUST be checked for safety, and that they conform to specification.
Supplementary Insulation
Apply 1250 volts rising to 2500 volts between laminations and spindle (A). See diagram.
Basic Insulation
Apply 750 volts rising to 1500 volts between commutator segments and laminations (B). See diagram.
Testing the
Armature

12
Service and Repair Manual
Model 2500V
1. Fit field coil (1) and brush holder housing (2)
together and secure with capscrews (3) and lock
nuts (5).
2. Refit the field assembly (1 & 2) into the top hous-
ing (4).
1. With service tool (see service tool list) refit the
pinion (2) with pinion spacer (7) (tighten clock-
wise to specified torque and remove service tool).
2. Press bearing (4) into bearing holder (3) and refit
circlip (5), fit brush springs (11) to brush
holder (12).
3. Fit spacer washer (8), fan (6), flat washer (9) and
lock nut (10) and tighten to recommended torque.
1. Fit spring anchor (4) and springs (2) into the
bearing housing (3) insert the armature assembly
into the top housing (5) and secure with three
screws (6) and washers (7), tighten to 6.0 Nm.
ASSEMBLY
Refitting the
armaturer
assembly
Assembling
the field
Assembling
the armature
43
2
5
1
6
5
4
2
3
7
8
10
9
1
23
4
5
Fig. 15
Fig. 16
Fig. 17
6
7
11 12

13
Service and Repair Manual
Model 2500V
1. Press the needle roller bearing (3) into the crank-
shaft housing (4).
2. Turn over the crankshaft housing, and press in
the roller bearing (2).
3. Refit the circlip (1).
1. Press needle bearing inner (6) on to the
crankshaft (1) and fit circlip (5).
2. Press big end needle roller bearing (7) into the
connecting rod (2), refit the thrust washer (8) to
the crankshaft, press the bearing inner ring (9)
onto the crankshaft (1), fit the connecting rod as-
sembly to the crankshaft, refit the thrust washer
(3), bearing retainer (10) and cap screw (4) and
tighten to the specific torque.
3. Insert the crankshaft assembly into the top hous-
ing through the barrel aperture.
1. Press the needle roller bearing (2) into the
layshaft housing assembly.
2. Refit the circlip (1).
3. Refit the seal (5) and seal assembly (3).
Assembling
the crankshaft
Assembling
the layshaft
housing
Assembling
the crankshaft
housing
1
3
2
13
2
5
1
3
2
56
4
10
897
Fig. 18
Fig. 20
Fig. 19
4
4

14
Service and Repair Manual
Model 2500V
1. Refit the layshaft housing assembly (4) and secure
with three capscrews (11). (Torque to 35 Nm).
2. Refit the crankshaft housing (8) feeding the
crankshaft (10) through the bearings in the crank-
shaft housing (it may be necessary to lightly tap
the crank into its final position after securing the
crankshaft housing) and secure with three
capscrews (12). (Torque to 35 Nm).
3. Fit the square key (9) to the slot in the crankshaft
(10).
4. Fit the crankshaft gear (7) onto the crankshaft
ensuring that the key stays in its slot.
5. Fit the dish spring washer (6), lock nut (5), the
dish spring washer is fitted with the outer edge of
the washer touching the gear and the centre of the
dish making contact with the lock nut, and
tighten the lock nut to 70 Nm.
6. Press needle roller bearings (2) into the layshaft
gear (1) (when pressing in the bearings these
should be fitted from both sides and not pressed
from one side).
7. Fit the thrust washer (14) and thrust bearing (3)
over the layshaft (13). Slide layshaft gear (1) onto
layshaft (13).
1. With pliers or suitable hook pull back the brush
spring (2) insert the carbon brush (3) (ensure that
the angle on the brush matches the spring to
maintain even pressure) release the spring to
make contact with the brush.
2. Fit the brush screw (4) and washer (5) and torque
to (3Nm).
3. Fit the brush cover (1) and secure with the screw
(6).
4. Repeat operation on opposite brush assembly.
Assembling
the gearbox
Fitting the
carbon
brushes
13
2
57
6
8
12
9
10
4
11
Fig. 21
Fig. 22
24
35
1
6
13
14

15
Service and Repair Manual
Model 2500V
1. Locate the switch box (4) with the O-ring fitted
into the top housing aperture, fit the power leads
(10) to one end of the switch (5) and the field
leads (9) to the opposite end of the switch. Locate
the switch into the switch sleeve (11), and then
locate the switch sleeve into the switch box (4).
Fit cord grip.
Note: The switch should be in the “OFF”
position, and the slot in the switch mounting
thread should be to the top when fitting, i.e.
towards the fan.
2. Fit the switch seal (6) to the switch (5).
3. Fit the switch box cover (7) and secure with four
pozi-screws.
4. Locate the switch actuator (2) through the switch
handle (8) into the trigger (3) fit the handle
assembly to the top housing whilst locating the
actuator (2) over the switch, and secure with four
capscrews.
5. Fit the springs (1) onto the switch actuator (2)
and check switch operation.
1. Fit the top cover (2) and secure with top cover
inserts (5) and four pozi-screws (6).
2. Fit the gear case cover gasket, and gear case (3)
and secure with six capscrews (7).
3. Fit handle (1) and secure with four capscrews (8).
4. Fit switch case cover (4) and secure with four cap
screws (10).
1. Fit the seals (5) to the piston (4).
Note: When fitting run a screwdriver around the
piston between the seal and piston to ensure
correct seating.
2. Fit the piston to the connecting rod (1) and push
the gudgeon pin (3) through, fit the two O-rings
(2) to the piston.
Assembling
the piston
Assembling
the switch
Fitting handle,
top cover and
gear case
cover
46
57
123 8 910
132
Fig. 23
1
6
34
2
8
9
5
10
7
Fig. 24
2
5
2
3
4
Fig. 25
1
11

16
Service and Repair Manual
Model 2500V
1. Fit the striker (11) over the piston (9), push on
with a twisting motion.
2. Place the top barrel gasket (1) onto the top
housing.
3. Fit the barrel (3) over the striker (11) and align
holes in barrel with the holes in the top housing.
Place the retaining rings (2) in the holes and
secure with the four capscrews (12) (torque to
130Nm).
Note: When the bolts reach their torque the plastic
should be visible around the head of the capscrew.
4. Fit recoil buffer (6) into buffer housing (5)
5. Fit anvil seal (8) onto anvil (7) and assemble into
buffer housing (5).
6. Fit buffer housing assembly into barrel (3).
Note: Smear Loctite 574 joint compound between the
barrel and anvil housing before fitting together. DO
NOT USE SILICONE SEALANT.
1. Insert the plunger and latch spring (5).
2. Fit the latch (4) and press down to over come the
spring tension, push the service tool (1) through
the latch to allow the tension pin (7) to be fitted to
it, press or knock the tension pin through until
flush, expelling the service tool (see diagram).
3. Fit the lock washer and flat washer to the latch
retaining bolt (6) and pass this through the
tension pin.
4. Fit the, flat washer, and lock washer to the
threaded end of the latch retaining bolt, and fit
the castellated nut (3).
5. Tighten the castellated nut and secure with the
split pin.
Assembling
the barrel
Assembling
the nosepiece
12
2
1
3
5
6
7
8
9
10
11
Fig. 26
Fig. 27
3
4
5
6
7
2
1
2
1
3
4
5
6
7

17
Service and Repair Manual
Model 2500V
1. Place the recoil buffer (1) into the nosepiece (2)
fit the assembly to the barrel, latch the same side
as the mains lead.
Note: Smear Loctite 574 joint compound between the
barrel and nosepiece before fitting. DO NOT USE A
SILICONE SEALANT.
2. Place the washer cup (3) and washer (4) into the
nosepiece (2) fit capscrews (5) and tighten
(torque to 130Nm).
Assembling
the nosepiece
Fig. 28
1
2
3
4
5

18
Service and Repair Manual
Model 2500V
With the aid of the Fault Finding chart (below) the source of any malfunction may be quickly 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
LETHAL VOLTAGES PRESENT!!
On completion of the assembly, the unit must be flash tested at 4000 volts.
1. With the breaker completely assembled and with the switch “ON” apply 2000 volts initially and
increase rapidly to 4000 volts between the main casting and one of the pins of the plug on the power
supply cord. Apply test to both live and neutral pins.
2. The full voltage of 4000 volts should be maintained without breakdown or flashover for a few sec-
onds.
3. If the armature has been tested, remove the carbon brushes before carrying out the test, (thus
avoiding over-stressing the armature insulation system.)
4. The test voltage must be applied between the main casting and each live pin of the plug in succes-
sion.
1. Ensure the unit is switched ON before testing. Operate the unit for approx. 10 minutes at half
voltage for initial ‘bedding in’ of the carbon brushes followed by full operational voltage. Compare
readings with Performance Data.
WARNING
Important
Flash Test
Running Test
FAULT FINDING