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

NO. Disassembly order and method Remark
1
2
3
4
5
6
7
★How to replace the handle
☞ Pull out the three #80 screws (M4*25) by turning them to the left with a
(+) screwdriver. Remove #78 bolt by turning it to the left with a 5mm L-
wrench and #79 bolt by turning it to the left with a 6mm L-wrench and
detach #74, #77 handle.
☞ Pull out the two #82 screws (M4*20) by turning them to the left with a
(+) screwdriver and detach the #81 cord clip.
☞ After replacing the handle, proceed with reassembling in reverse order
of disassembling.
★How to replace the cord
☞ (Proceed with disassembling procedures 1 and 2.) Pull out the brown
line from the #3 terminal of the #76 switch by turning them to the left
with a (+) screwdriver. Detach the blue line from the #4 terminal of the
#76 switch by turning the terminal with a (+) screwdriver. (See the
connection terminals of the upper switch)
☞ Detach the #83 cord armor from #84 cord.
☞ After replacing the cord, proceed with reassembling in reverse order of
disassembling.
★How to replace the switch
☞ (Proceed with disassembling procedures 1,2 and 4) Pull out the black
stator lead wire and capacitor from the #1 terminal of the #76 switch
by turning them to the left with a (+) screwdriver. Detach red stator
lead wire and capacitor from the #2 terminal of the #76 switch by
turning the terminal with a (+) screwdriver.
☞ After replacing the switch, proceed with reassembling in reverse order
of disassembling.
[Caution
1]
assembly, capacitor and
When reassembling, be
to avoid #70
bellows (B) from being
When reassembling the
switch
picture.
♠ Be careful not to
lose
#71 damper (A)
#73, #75 nut.
[Caution
2]
♠
careful
bellows (A) and
#65
pinched.
[Caution
3]
♠
handle, be careful to
avoid the wire from
being pinched.
♠ See the
connection
- 11 -
80
79
83
65
78
84
82
75
76
71
77
70
74
73
81
Swi ch
connec ion erminals
Swi ch connec ion

8
Disassembly /
Assembly No. 03 Disassembly/ Assembly Name How to replace the armature
- 12 -

NO. Disassembly order and method Remark
1
2
3
4
5
6
7
8
☞ Remove #78 damper bolt by turning it to the left with a 5mm L-wrench
and remove it from #41 crank case by pulling the handle backward.
☞ 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)
☞ Pull out the four #59 bolts (M6*55) by turning them to the left and
detach from the #47 gear cover.
☞ Using a hand press, remove #51 armature assembly from #47 gear
cover.
☞ After removing #48 bearing (6201) and #46 bush together with a
bearing puller, remove #54 rubber packing and remove #53 bearing
(608ZZ) with a bearing puller.
☞ Detach the #49 dust plate(A) and the #52 dust plate(B) from the #51
armature assembly.
☞ After replacing the armature, proceed with reassembling in reverse
order of disassembling.
♠ When assembling the handle, striking the “A” side of the handle
will make the assembling easier.
[Caution 1]
damage #60 brush cap.
Be careful not to lose the
damper assembly in the
When reassembling, be
careful not to lose #49
dust plate(A), #52 dust
plate(B) and direction of
When reassembling, be
to lose #54
, #92
, #93 seal
♠ Be careful not
to
[Caution 2]
♠
inside of the handle
assembly.
[Caution 3]
♠
assembly.
[Caution 4]
♠
careful not
rubber
packing
washer(B)
packing.
Disassembly /
Assembly No. 04 Disassembly/ Assembly Name How to replace the stator/housing
- 13 -
67
66
46
48
52
60
51
47
64
78
54
59
41
49
53
58
“
A”
Assembling direc ion of
#49 dus pla e A)(
Assembling direc ion of
#52 dus pla e (B)
73
92
93
93
When reassembling, pu he
seal packing on he surface
of gear cover.

NO. Disassembly order and method Remark
1
2
3
4
5
6
7
8
☞ Pull out the three #80 screws (M4*25) by turning them to the left with a
(+) screwdriver. Remove #78 bolt by turning it to the left with a 5mm L-
wrench and #79 bolt by turning it to the left with a 6mm L-wrench and
detach #74, #77 handle.
☞ Pull out the black stator lead wire and capacitor from the #1 terminal of
the #76 switch and red wire and capacitor from #2 terminal by turning
with a (+) screwdriver. (See the picture of the connection terminals
of the upper switch)
☞ 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 #60 brush cap by turning it to the left with a (-) screwdriver
and detach the #74 carbon brush. (Do the same for the opposite side)
☞ Pull out the four #59 screws (M6*55) by turning them to the left and
detach the #58 housing from the #47 gear cover.
☞ Detach the # 55 fan guide from the #58 housing.
☞ Pull out the two #57 screws (M5*55) by turning them to the left with a
(+) screwdriver and detach the #56 stator from the #58 housing. (As
the stator is pressed hot, reassembling must be done after heating the
housing with a hot air blower)
☞ After replacing the stator or housing, proceed with reassembling in
reverse order of disassembling.
[Caution 1]
♠ When reassembling the
handle, be careful to
avoid the wire from being
pinched.
♠ See the switch
connection picture.
[Caution 2]
♠ Be careful not to
damage #60 brush cap.
[Caution 3]
♠ When reassembling, be
careful not to lose #54
rubber packing.
[Caution 4]
♠ Be careful not to lose
#71 damper (A)
assembly, capacitor and
#73, #75 nut.
- 14 -
78
79
80
Swi ch
connec ion
erminals
71
56
66
57
59
55
47
58
60 64
67
77
76 75
73
Swi ch connec ion
74
54

Disassembly /
Assembly No. 05 Disassembly/ Assembly Name How to replace the side handle
NO. Disassembly order and method Remark
1
2
3
☞ Detach the #89 clamping nut from the #85 side handle by turning the
side handle to the left.
☞ Remove #86 bolt (M8*140).
☞ Remove #88 holder and #87 holder band by turning #85 side handle to
the left.
[Caution 1]
♠ When assembling, be
careful of the orientation of
the holder.
[Caution 2]
♠ When mounting/removing
the holder, remove the
rubber jacket first as the
tension of the holder is very
high.
- 15 -
85
89
88
87
86

Disassembly /
Assembly No. 06 Disassembly/ Assembly Name How to replace the front cover/bit guide
NO. Disassembly order and method Remark
★How to replace the front cover [Caution 1]
- 16 -
13
27
12
9
19
2
1
10
6 8
5
21
7
20
7
35
36
14
26
11
37
15
3
4
28
41
Assembling direc ion of
damper washer Assembling direc ion of
ca cher

1
2
3
4
5
6
7
8
9
10
11
12
☞ Detach the #35 jacket from the #26 cylinder case.
☞ Remove #1 dust cap with a (-) screwdriver. Once #1 dust cap
has been removed, #2 retainer, #3 spring and #13 guide pin
can be removed.
☞ Using a ring pincer, remove #4 retaining ring from #14 bit
guide. Once the retaining ring has been removed, #5
selector guide, #6 selector and #9 steel ball can be removed.
☞ Pull out the four #7 bolts (M4*16) by turning them to the left
and detach #36 grease cover and #37 O-ring (B).
☞ Pull out the one #7 bolt (M4*16) by turning it to the left. Using
a rubber hammer, remove #8 crank case cover (B) from #41
crank case.
☞ Pull out the four #27 bolts (M6*30) by turning them to the left
and detach #26 cylinder case and #41 crank case.
☞ After fi ing #26 cylinder case to the fi ing device, detach #10
front cover from #41 crank case by turning the front cover to
the left.
☞ Remove #10 front cover and #14 bit guide.
☞ Detach the #11 O-ring(C) from the front cover.
☞ After replacing the front cover, proceed with reassembling in
reverse order of disassembling.
★How to replace the bit guide
☞ (Proceed with disassembling procedures No.1~No.8) Detach
the #15 anvil from the #14 bit guide and detach the two #12
O-rings (S28).
☞ After replacing the bit guide, proceed with reassembling in
reverse order of disassembling.
retaining ring, be careful to
avoid it from losing
ing #6
selector, be careful not to
When
reassembling, coating the
balls with grease will make the
reassembling
When reassembling, be careful
not to omit #11 O-
-ring (D).
ng #19,
and 21, make sure that
they are assembled in the right
direction and in right sequence.
The edged plane of #19
damper washer must face
toward the slanted plane of the
anvil. The grooved section of
#21 catcher must face crank
♠ When removing #4
elasticity.
[Caution 2]
♠ When remov
lose #9 steel ball.
easier.
[Caution 3]
♠
ring (C), #28 O
[Caution 4]
♠ When reassembli
20
toward #41
Disassembly /
Assembly No. 07 Disassembly / Assembly Name How to replace the cylinder case
- 17 -

NO. Disassembly order and method Remark
1
2
3
4
5
6
7
8
9
10
]
11
☞ Detach the #35 jacket from the #26 cylinder case.
☞ Remove #1 dust cap with a (-) screwdriver. Once #1 dust cap has been
removed, #2 retainer, #3 spring and #13 guide pin can be removed.
☞ Using a ring pincer, remove #4 retaining ring from #14 bit guide. Once
the retaining has been removed, #5 selector guide, #6 selector and #9
steel ball can be removed.
☞ Pull out the four #7 bolts (M4*16) by turning them to the left and detach
#36 grease cover and #37 O-ring (B).
☞ Pull out the one #7 bolt (M4*16) by turning them to the left. Using a
rubber hammer, remove #8 crank case cover (B) from #41 crank case.
☞ Pull out the four #27 bolts (M6*30) by turning them to the left and
detach #26 cylinder case and #41 crank case.
☞ After fi ing #41 cylinder case to the fi ing device, detach #10 front
cover from #41 crank case by turning the front cover to the left.
☞ Remove #19 damper washer, #20 damper (B), #21 catcher and #22
striker in the right sequence and direction.
☞ Detach the #30 ring spring and detach #25 cylinder from #26 cylinder
case.
☞ Remove #29 sleeve by striking the sleeve side of the inside #26
cylinder case with a rubber hammer. (See upper picture)
(When disassembling, heat up the cylinder case with a hot air heater)
☞ After replacing the cylinder case, proceed with reassembling in reverse
order of disassembling.
♠ When reassembling the cylinder and the sleeve, make sure that
they are assemble in the right direction!(See upper picture)
[Caution 1]
assembling, heat
cylinder case with
r heater before
the sleeve.
When reassembling #19,
and 21, make sure that
they are assembled in the
right direction and in right
sequence. The edged
plane of #19 damper
washer must face toward
the slanted plane of the
grooved section
catcher must face
striker.
When adding the grease
to supplement the loss of
disassembling, coat each
When reassembling, be
careful not to omit #11
O8 O-ring (D).
♠ When re up
the a hot ai
assembling
[Caution 2]
♠ 20
anvil. The of
#22 toward
#16
[Caution 3]
♠
grease during
part with grease.
[Caution 4]
♠
ring (C), #2
- 18 -
20
41
25
9
16
6
1
10
37
14
26
6
11 36
24
11
Assembling direc ion
of cylinder
Declara ion
of
ma erial
12<ALDC>
13
Assembling
direc ion of sleeve
27
30
29
S rike wi h a
hammer
19
28
7
3 5
4 8
21
22
2 35

Disassembly /
Assembly No. 08 Disassembly / Assembly Name
How to replace the connecting
rod/piston
NO. Disassembly order and method Remark
1
2
3
4
5
6
7
8
9
10
☞ Detach the #35 jacket from the #26 cylinder case.
☞ Remove #1 dust cap with a (-) screwdriver. Once #1 dust cap has been
removed, #2 retainer, #3 spring and #13 guide pin can be removed.
☞ Using a ring pincer, remove #4 retaining ring from #14 bit guide. Once
the retaining has been removed, #5 selector guide, #6 selector and #9
steel ball can be removed.
☞ Pull out the four #7 bolts (M4*16) by turning them to the left and detach
#36 grease cover and #37 O-ring (B).
☞ Pull out the one #7 bolt (M4*16) by turning it to the left. Using a rubber
hammer, remove #8 crank case cover (B) from #41 crank case.
☞ Pull out the four #27 bolts (M6*30) by turning them to the left and
detach #26 cylinder case and #41 crank case.
☞ Remove #31 piston assembly (#11 O-ring 30 (F), #32 O-ring (E), #33
piston pin, #34 connecting rod) from the crank shaft as shown in the
picture on the left.
☞ After removing #32 O-ring (E), detach #33 piston pin from #31 piston.
☞ Detach the #30 O-ring (F) from the #31 piston.
☞ After replacing the connecting rod/piston, proceed with reassembling in
reverse order of disassembling.
[Caution 1]
♠ Supplement appropriate
amount of grease
(1015g) as loss of some
grease may occur
during replacement
work.
[Caution 2]
♠ When reassembling
select, be careful not to
lose #9 steel ball.
[Caution 3]
♠ When reassembling, be
careful not to lose #28
O-ring(D).
[Caution 3]
♠ When reassembling,
orient the crank shaft as
shown in the picture
above before mounting
the piston assembly.
- 19 -
13
28
8
1
2
36
27
9
Se he connec ing par of he connec ing rod of he
crank shaf a an angle of abou 5˚ before
assembling/disassembling he pis on.
7
35
37
33
30
41
34
26
5˚
32
31
4 6
3 5
7

Disassembly /
Assembly No. 09 Disassembly / Assembly Name How to replace the crank case
NO. Disassembly order and method Remark
1
2
☞ Detach the #35 jacket from the #26 cylinder case.
☞ Remove #1 dust cap with a (-) screwdriver. Once #1 dust cap has
[Caution
1]
- 20 -