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Kango 2500 Service And Repair Manual

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Summary of Contents for Kango 2500

  • Page 2: Torque Settings

    Service and Repair Manual Model 2500V ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 9170 0739 60 10mm HEX. SOCKET, 3/8" SQ. DRIVE. 9170 0737 10 ASSEMBLY CRANKSHAFT NEEDLE BEARING 9170 0731 90 7/8" BSF HEX. SOCKET 9170 0230 30 ASSEMBLY ARMATURE SEAL ASSY 9170 0735 50 24mm HEX.
  • Page 3 Service and Repair Manual Model 2500V 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.
  • Page 4 Service and Repair Manual Model 2500V Dismantling the 1. Remove the buffer housing (2) from the barrel and barrel push out the anvil (4). 2. Remove the recoil buffer (3) with a screwdriver. 3. With a screwdriver remove the anvil seal (5). 4.
  • Page 5 Service and Repair Manual Model 2500V Removing the 1. Remove the four pozi-screws from the switch cover switch (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.
  • Page 6 Service and Repair Manual Model 2500V Removing the 1. Remove the circlip (1) from the crankshaft housing bearings from and press out the bearing (2), see service tool list. the crankshaft 2. Turn housing over and press out needle roller bearing (3), see service tool list.
  • Page 7 Service and Repair Manual Model 2500V Removing the 1. Remove the three screws (1) and washers (2) from armature 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). Fig.
  • Page 8 At service and repair intervals the lubrication should be carried out as shown in the diagram below. All Lubrication 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.

  • Page 9: Electrical Testing

    Testing the Supplementary Insulation Armature 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. ELECTRICAL PERFORMANCE TEST READINGS...
  • Page 10 Service and Repair Manual Model 2500V ASSEMBLY Assembling 1. Fit field coil (1) and brush holder housing (2) the field together and secure with capscrews (3) and lock nuts (5). 2. Refit the field assembly (1 & 2) into the top hous- ing (4).
  • Page 11 Service and Repair Manual Model 2500V Assembling 1. Press the needle roller bearing (3) into the crank- the crankshaft shaft housing (4). housing 2. Turn over the crankshaft housing, and press in the roller bearing (2). 3. Refit the circlip (1). Fig.
  • Page 12 Service and Repair Manual Model 2500V 1. Refit the layshaft housing assembly (4) and secure Assembling with three capscrews (11). (Torque to 35 Nm). the gearbox 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...
  • Page 13 Service and Repair Manual Model 2500V 1. Locate the switch box (4) with the O-ring fitted Assembling into the top housing aperture, fit the power leads the switch (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).
  • Page 14 Service and Repair Manual Model 2500V 1. Fit the striker (11) over the piston (9), push on Assembling with a twisting motion. the barrel 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.
  • Page 15 Service and Repair Manual Model 2500V Assembling 1. Place the recoil buffer (1) into the nosepiece (2) fit the assembly to the barrel, latch the same side the nosepiece as the mains lead. Note: Smear Loctite 574 joint compound between the barrel and nosepiece before fitting.

  • Page 16: Fault Finding

    Service and Repair Manual Model 2500V WARNING LETHAL VOLTAGES PRESENT!! On completion of the assembly, the unit must be flash tested at 4000 volts. Important 1. With the breaker completely assembled and with the switch “ON” apply 2000 volts initially and Flash Test increase rapidly to 4000 volts between the main casting and one of the pins of the plug on the power supply cord.