Keyang KH-5000M User manual

A/S Manual
(KH-5000M Disassembly/Assembly)
- 1 -

Contents
<Explode iew>
<Part List>
<Diagnoses and solutions to each type of problem>
< 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
77
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
3
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
of
Problem
Location
of
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
e

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
of
Problem
Location
of
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
e
Overheain
g

■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
of
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
1
2
3
4
5
★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 -
47
58
67
60
64
66
61
60