Kangol 845S User's Manual
Contents
1. KANG 845S Date Code 0001L2001 9800 0332 01 a T KANGO Service and Repair Manual Model 845S 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 occuring ALL SEALS GASKETS GREASE OR OTHER PARTS DEEMED NECESSARY FOR SERVICING ARE IN THE SERVICE KIT ALLNEEDLE ROLLER BEARINGS SHOULD BE PRESSED WITH THE ROUNDED EDGE ENTERING 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 ISRECOMMENDED Inspection All mechanical and electric parts should be inspected for wear and replaced as required WARRANTY AND LIABILITY Use only Authorized parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability SERVICE TOOLS All repairs may be completed with standard workshop tools and equipment Model 845S e F KANGO Service and Repair Manual EXAMPLE Component Parts Small Are Included When Ordering The Assembly Large A SEE PAGE 5 FOR ADDIT2. DO NOT CREATE TWO SETS OF THREADS IN ONE HOLE KANGO Service and Repair Manual Model 845S As an aid to reassembly take note of wire routing and position in wire guides and traps while dismantling tool Tuck all wiring into left handle half prior to assembling right handle half This will avoid pinched wires Brush shunt wires to be positioned up in brush tube slots as shown for full travel Check that there is clearance between the SWITCH CONNECTIONS 8 Bottom view A Keep leads Fast on away from terminals must be potential fan and brush shunt completely connected pinch points ae wires between leads 4 and 9 rush to brush plate Wrap wire tie around electronics boat to retain leads as shown 1 2 connections r A LAY A 7 Ka must be seated in slot located on brush tubes E Tuck leads EA p 5 and 6 lagi ma BRUSH CARD away from ASSEMBLY armature Cord to be inserted into clamp Xj Dy trap Cord to extend 1 4 minimum above top of CS clamp For 120 V only See below for 110 V and 230 V 110 V and 230 V QUIK LOK CORD ORIENTATION WIRING SPECIFICATIONS lii Assembly Wire Wire Color Origin or No 110 V 120 V 230 V Part No Connection Cord Switch t Cord Switch Field Lead 9 Inductor Boat Field Switch Field Brush Holder Field Brush Holder WIRING Motor Con
3. Rod 120 9170 3258 20 Band Retainer 121 9170 4668 40 Side Handle Housing 9170 4668 50 Nose Service Tool Apply 5 oz grease on clutch assembly filling the spring coils Seal to be installed with f garter spring to left as shown Dip Felt Washer 106 into light oil Press Oil Seal 102 and Felt Washer into Nose 48 to dimension shown using Nose Service Tool 9170 4668 50 Lightly grease Spring 74 and bit lock 91 SERVICE CARRYING CASE No 9170 4667 20 KA Lubricate O Ring with grease Install O Ring onto Ram Assemble Cap Seal onto Ram k Resize Cap Seal and load into Xx Barrel seal end first Ram Place 5 oz grease in should be located flush with lower clutch pinion cavity end of Barrel Model 845S KANGO Service and Repair Manual INSERT SMALL FIG A NOTES SCREW DRIVER 54 55 56 TOREMOVE BELLY SHROUD 56 FROM TOOL INSERT SMALL SCREW DRIVERINTOGROOVEBETWEENBELLYAND SIDE SHROUDS 54 AND 55 ABOUT 1 3 OF THE WAY FROM THE MOTOR END AS SHOWN PRY OUT AND DOWN ON BOTH SIDES OF THE TOOL TO INSTALL THE SIDE SHROUDS 54 AND 55 THE TOP HINGE OF THE SHROUDS MUST BE COMPLETELY INTERLOCKED THEN THE BACK SIDE ROTATED CLOSED AROUND THE TOOL 54 55 73 LUBRICATE ALL BORES IN SPINDLE 73 WITH A MEDIUM COATING OF GREASE 63 108 109 LUBRICATE RUBBER DAMPING WASHER 63 BARREL THRUST WASHER 108 AND STRIKER CUSHION WASHER 109 WITH A MEDIUM COATING O
4. 00 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 seconds If the armature has been tested remove the carbon brushes before carrying out the test thus avoiding overstressing the armature insulation system 4 The test voltage must be applied between the main casting and each live pin of the plug in succession Running Test 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 FAULT FINDING With the aid of the Fault Finding chart below the source of any malfunction may be quickly identified and repaired MACHINE MOTOR HAMMERS REVOLVES ARMATURE FIELD INTERNAL WIRING WAS SERVICE MECHANISM MOTOR BURNT MODULE OUT MACHINE OK Atlas Copco Berema AB Sickla Industrivag 1A S 105 23 Nacka Sweden Telephone 46 0 8 743 9600 Fax 46 0 8 743 9650 9800 0332 01 a 54 24 0975 Drwg 3 04 02
5. F GREASE BEFORE ASSEMBLY 10 100 PRESS NEEDLE BEARING 10INROD 100 SO THAT THE SAME AMOUNT STICKS OUT ON BOTH SIDES OF THE ROD AS SHOWN 9 71 PRESS 2 NEEDLE BEARINGS 9 INTO HOLLOW CLUTCH SHAFT 71 FLUSH WITH THE ENDS OF THE SHAFT 11 12 46 PRESSNEEDLE BEARINGS 11 AND 12 FLUSH TO THE MACHINED FACES ON BOTH ENDS OF THE INTERMEDIATE HOUSING 46 9 44 PRESS NEEDLE BEARING 9 INTO CRANKCASE 44 FLUSH WITH TOP OF BORE AS SHOWN 81 LIGHTLY GREASE INSIDE OF BARREL 81 BEFORE ASSEMBLY 48 73 SMALL OUTSIDE DIAMETER OF SPINDLE 731S TO BELUBRICATED WITHA LIGHT COAT OF GREASE BEFORE ASSEMBLING THE NOSE ASSEMBLY 48 TO THE TOOL 48 73 102 NOSEASSEMBLY 48 MUST BE PLACED SQUARELY OVER SPINDLE 73 WHEN ASSEMBLING TO PREVENT DAMAGE TO OIL SEAL 102 14 19 20 23 FASTENERS 14 19 20 AND 23 ARE TO BE RE ASSEMBLED USING BLUELOCTITE 48 102 LUBRICATE BOREIN NOSE ASSEMBLY 48 BEFORE PRESSING OIL SEAL 102 INTO PLACE 60 61 62 LUBRICATE O RINGS 60 61 62 66 AND 67 WITH GREASE 66 67 69 INSTALL BEVEL SNAPRING 69 WITH BEVEL SIDE UP 4 50 80 PLACEBEARING CUP 80 ON SMALL ARMATURE BEARING 4 BEFORE INSTALLING MOTOR COVER 50 41 BRUSH SPRINGS 41 ARE TO BE WOUND 172 TURN TO ENGAGE BRUSHES 4 RUBBER SEAL SIDE OF BALL BEARING 4 TO FACE FAN 95 98 FACES OF PISTON 95 AND RAM 98 ARE TO BE FREE OF GREASE 105 WHEN REASSEMBLING BARREL AND CLUTCH SCREWS INTO EXISTING CRANKCASE MAKE SURE SCREWIS STARTED IN EXISTING THREAD
6. IONAL LUBRICATION AND SERVICE NOTES FIG PARTNO DESCRIPTION OF PART NO REQ 41 9170 3252 10 Brush Spring 2 42 9170 4652 10 Speed Control Switch 47 9170 3254 10 Upper Handle Mount 50 9170 4652 30 Motor Cover 51 9170 4656 80 Left Handle Half FIG PARTNO DESCRIPTION OF PART NO REQ 52 9170 4657 60 Right Handle Half 2 9170 4667 30 5mm Steel Ball 53 9170 4658 40 Motor Housing 4 9170 325120 Ball Bearing 54 9170465940 Left Shroud 7 9170325160 Ball Bearing 55 9170465950 Right Shroud 13 9170 325310 Pivot Nut 56 9170465990 Belly Shroud 15 9170325290 Pivot Bolt 59 9170325150 Retaining Ring 16 9170325100 M6x1 0x 120 Pan Hd Slit Tapt T 27 62 9170325080 O Ring 19 9170325390 Special Screw 76 9170325070 Retaining Ring 20 9170325010 8 32 x 3 8 Pan Hd Sit Tapt T 20 77 9170325050 Torsion Spring 21 9170325190 8 16 x 2 Pan Hd Sit Plast T 20 79 91703250 30 Compression Spring 24 9170325250 M5x2 24x 18 Pan Hd Sit PT T 20 80 9170 3251 10 Bearing Cup 25 9170465010 Dowel Pin Knurled 9170 4660 20 Shift Disk 26 9170465270 Round Label 87 9170 3254 20 Isolation Bellows 31 9170465060 Electronics Assembly 88 9170325300 Pivot Isolator 32 91704650 80 120 Volt Armature 89 9170 3254 30 Isolation Module Assembly 33 91704651 70 120 Volt Field 90 9170325020 Rotostop Knob 34 9170323720 120 V Carbon Brush 2 Kit 92 91703253 30 Foam Slug Kit Bag of 10 36 9170325200 Brush Carrier Assembly 93 9170325260 Handle Cushion 39A 9170 3253 50 Lower Cord Clam
7. RT NO REQ LUBRICATION NOTES TYPE S2 GREASE NO 9170 4664 70 9170 3256 50 1 8 Steel Ball 12 9170 4661 10 1 4 Steel Ball 1 9170 3254 90 Ball Bearing 1 3 5 Fill Piston 95 with grease and 6 9170 3256 20 Ball Bearing 8 9 assemble to Connecting Rod 100 with Wrist Pin 94 Front surface of Piston to be free of grease Lubricate O Ring 67 _ with grease Place a total of 1 0 0z grease in the barrel cavity in the crankcase 44 Place 5 oz in each corner in barrel chamber 9170 3257 20 Ball Bearing 9170 3255 70 Needle Bearing 10 91703255 20 Needle Bearing 11 9170326000 Needle Bearing 12 9170326030 Needle Bearing 14 91704661 90 M6x1 0x 70 Skt Hd Cap Scr T 27 17 9170466200 Cross Pin 18 9170325810 Dowel Pin 22 9170325460 8 32 x 3 8 Pan Hd Sit Taptite T 20 23 9170325470 M4x0 7x 14 Pan Hd Sit Taptite T 20 28 9170 3257 80 External Retaining Ring 43 9170325590 Bearing Retainer 44 9170466210 Crankcase 45 9170325440 Crankcase Cover 46 9170 4662 30 Intermediate Housing 48 9170466250 Nose Assembly 49 9170 3254 50 e Cap Cover 57 9170 3257 30 Bevel Gear 58 9170 4662 90 e Cap Seal 60 9170 4664 40 e O Ring 61 9170325580 O Ring 63 9170 3261 00 e Rubber Damping Washer 64 9170 3255 00 e Seal Cover 1 5 oz of crankcase prior to 5 a lt Q installing crankshaft gt assembly 65 9170 4664 60 e O Ring 66 9170 3255 50 67 9170 4665 50 e O Ring 68 9170325740 Re
8. p 110 9170 3254 00 Rubber Washer 39B 9170 4665 60 Upper Cord Clamp 114 9170466090 Fan 40 9170465190 Cord Set 123 9170 3253 80 Cord Protector nr LL oo L2 oc ll LL nn n on cc 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 2 1 1 Rn nn nn nnn non no en et a mi a 2 a SD AD BR es NN RN NN NR Rn RR nn nnn nnn nn nn nnn EEE aa a aa anaana ees Service and Repair Manual Model 845S NOTE USE OIL ON ALL AREAS TO BE PRESS FIT Assemble Thrust Washers 107 and Belleville Spring Washers 78 into Intermediate Housing 46 as illustrated FASTENER TORQUE SPECIFICATIONS IN LBS SEATING TORQUE FIG NO MINIMUM MAXIMUM 9170 3237 20 CARBON BRUSH SERVICE KIT THIS KIT CONTAINS Carbon Brush 4 1 9170 326100 Rubber Damping Washer 1 9170 3255 00 Seal Cover 1 91704664 60 O Ring 1 9170325550 O Ring 1 9170 466290 Cap Seal 1 81704664 40 O Ring AND SHROUDS gt ad 1 9170466550 O Ring s 1 9170325110 Bearing Cup 15 al 7 1 9170326140 Gasket 1 1 1 1 9170 4660 00 HAMMER SERVICE KIT THIS KIT CONTAINS 9170 3254 50 Cap Cover 9170 4672 30 9170 4672 40 9170 4672 50 9170 3237 20 Dust Seal Hex Dust Seal Round 7 Oz Tube S2 Grease Carbon Brush Service Kit FOR ADDITIONAL AND SERVICE NOTES A SEE PAGE 5 LUBRICATION Model 845S KANGO Service and Repair Manual FIG PARTNO DESCRIPTION OF PA
9. taining Ring 69 91703254 80 Retaining Ring Beveled 70 91704665 70 Clutch Shaft O Ring FRONT OF CRANKCASE Apply grease to Apply grease to spline lobed surface 97 0 surface 71 71 9170 325710 Hollow Clutch Shaft 72 9170325560 Crankshaft Assembly Apply grease to 73 9170 4666 20 Spindle lobed surface 96 74 9170 4666 80 Bit Lock Spring 75 9170 3256 80 Compression Spring 78 9170 3260 20 Belleville Spring 81 9170 4667 40 Barrel 83 9170325690 Spring Flange 84 9170 3261 40 e Gasket 91 9170466750 Bit Lock 94 9170466160 Wrist Pin 95 91704667 60 Piston 96 9170 3256 70 Splined Clutch Plate 97 9170 3256 60 Fixed Clutch Plate 98 9170466770 Ram 99 91703256 40 Shift Ring 100 9170 325510 Connecting Rod Assembly 101 9170 4667 80 e Dust Seal Hex 5 pkg 9170 4667 90 Dust Seal Round 5 pkg 102 9170466300 OilSeal 104 9170 4668 00 Striker 105 9170466810 DG50 x 16mm Torx Pan Head Screw 106 9170 4664 20 Felt Seal 107 9170326010 Thrust Washer 108 9170326110 Barrel Thrust Washer 109 9170 3260 90 Striker Cushion Washer 113 9170 3257 90 Wave Washer 115 9170 4651 60 Hex Head Bolt Special 116 9170 4668 20 Side Handle Band 117 9170 3257 70 Side Handle Assembly 118 9170 4666 30 Depth Rod Mount Assembly 119 9170 325760 Depth Gauge
10. trol Assy Switch SCHEMATIC Motor Control Assy Switch Motor Control Assy Lead 3 KANGO Service and Repair Manual Model 845S ELECTRICAL TESTING Electrical test Before assemby all electrical parts MUST be checked for safety and that they conform to specification Testing the Armature Flash Testing A Armature shaft to lamination pack B Lamination pack to commutator C Armatuure shaft to commutator 1500 Volts min 1200 Volts min 3000 Volts min ELECTRICAL PERFORMANCE TEST READINGS ARMATURES MODEL 110V 120V 220V 240V 845S 440 506 Ohms 440 506 Ohms 1 283 1 477 Ohms FIELD COILS 845S 110V 120V 220V 240V 349 401 Ohms 349 401 Ohms 1 339 1 54 Ohms PERFORMANCE Running No Load 845S 110V 120V 220V 240V 4 5 6 5 Amps 4 5 6 5 Amps 2 9 4 4 Amps CLUTCH SLIP Measured on disassembly assembly 35 45ft Ibs 47 61Nm Non Electrical Test Note On all test readings or 5 of figures shown is acceptable KANGO Service and Repair Manual Model 845S WARNING LETHAL VOLTAGES PRESENT IMPORTANT On completion of the assembly the unit must be flash tested at 4000 volts Flash Test 1 With the breaker completely assembled and with the switch ON apply 2000 volts initially and increase rapidly to 40
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