Kangol 840M User's Manual
Contents
1. 840M Date Code 001112001 9800 0329 01 a KANGO Service and Repair Manual Model 840M 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 ALL NEEDLE 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 IS RECOMMENDED Inspection All mechanical and electric parts should be inspected for wear and replaced as required WARRANTY AND LIABILITY STATEMENT 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 RANGO Model 840M Service and Repair Manual FIG Component Parts Small Are Included When Ordering The Assembly Large EXAMPLE PART NO 9170 4650 00 9170 4672 80 92. NOTE Do not dislodge the bearing cup from the bearing during assembly Service and Repair Manual Model 840M SWITCH BACK VIEW BRUSH CARD WIRING SCHEMATIC BLADE ELECTRONICS ASSEMBLY NOTE Module wires 3 and 4 are not polarity sensitive WHITE BLACK TERMINAL DESCRIP Origin or Gauge Terminals Connectors and 1 or 2 End Wire Preparation Blade Hsg Component of blade housing assembly Blade Hsg Component of blade housing assembly T1 9170466690 2 Elect Mod Component of electronics module Strip 1 4 for T1 Elect Mod Component of electronics module Strip 1 4 for T1 KANGO Service and Model 840M Repair Manual 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 1500 Volts min A Armature shaft to lamination pack B Lamination pack to commutator 1200 Volts min C Armatuure shaft to commutator 3000 Volts min A l e AE a a I Be ef C ELECTRICAL PERFORMANCE TEST READINGS ARMATURES MODEL 110V 120V 220V 240V 840M 440 506 Ohms 440 506 Ohms 1 283 1 477 Ohms FIELD COILS 840M 110V 120V 220V 240V 349 401 Ohms 3849 401 Ohms 1 339 1 54 Ohms PERFORMANCE Running No
3. needed wipe off with a dry rag Coat gearcase seal 62 with lubrication prior to placement in the gearcase 38 Use Blue L FASTENER TORQUE SPECIFICATIONS IN LBS Loctite ATIN ORG 242 on Screws 24 two places 1 NOU VIUN VILO IV 120 130 FT LBS 200 FT LBS 130 FT LBS 200 FT LBS Switch Screws 4 6 Model 840M MANGO Service and Repair Manual FIG PART NO DESCRIPTION OF PART NO REQ 2 9170 3254 90 Ball Bearing 5 91704650 40 Ball Bearing 6 9170 467280 Vent kit 7 9170325520 Needle Bearing 9 9170 465070 M6 Socket Head Cap Screw 12 9170465100 K35 x 8mm Pan Hd Plastite Screw 18 9170466320 Split Sleeve 20 9170325810 Dowel Pin 24 9170325460 Slotted Taptite Torx Screw 25 9170465220 K50 x 22mm PT DG Screw 36 9170465330 SDS Max Nose Service Assembly 37 9170465460 Crankcase Assembly 38 91704671 70 Gearcase Service Kit 39 9170465280 Crankshaft Assembly 43 9170 4655 10 O 5 8 Cap Plug 44 9170465520 Screw Cap 48 91704666 30 Depth Rod Mount Assembly 49 9170325800 Side Handle Housing 54 9170465650 Main Shroud 55 91704656 70 Locking Ring 56 9170325860 Spacer 57 9170 4666 40 Clutch Gear Assembly 58 9170465710 Drive Gear 62 9170 4657 40 Gearcase Seal 64 9170 3255 50 O O Ring 65 9170 4657 70 O Capseal 67 9170465790 O Ring 68 9170 4658 00 O Ring 69 9170465810 O Ring 70 9170 4658 20 O O Ring 71 9170 4658 30 O Damping Wash
4. Load 840M 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 40 50ft Ibs 47 61Nm Non Electrical Test Note On all test readings or 5 of figures shown is acceptable KANGO Service and Repair Manual Model 840M 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 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 The full voltage of 4000 volts should be maintained without breakdown or flashover for a few seconds 3 Ifthe 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 ARMATURE MIELO INTERNAL W
5. Press 6 flush to top of 37 NP Fill Piston 102 with S2 grease and as semble to Connecting Rod 109 with the Wrist Pin 101 Front surface of Piston 102 and the Ram 103 is to be free of grease NM Lubricate the O Ring 68 102 with grease 6a Lightly coat the inside of the Barrel 87 with grease prior to assembly Lightly coat the inside bore of the 87 7 Spindle 74 prior to the insertion of the Striker 115 A SEE PAGE 6 FOR ADDITIONAL SERVICE NOTES Place 1 0 oz of grease in the barrel area of the Crankcase 37 Apply a light coat of grease to the Drive Gear 58 prior to assembly Prior to assembly apply a light coat of grease to the Gearcase Seal 62 and O Rings 63 64 67 68 and 70 KANGO Service and Repair Manual Model 840M T li Ji 30 A Miki 3 Mi OVI SS E Press metal insert of li fan to here CAT IC A N ee on H RT a aN YAS DOL ASS Gi N Mm gt Press fan 3 onto armature 30 AN IH ZRH such that the metal insert of the fan IN bottoms against the fan journal E ui ns h oud shoulder of the armature shaft I After the armature assembly 30 is installed into the tool the bearing cup 86 is to be placed on the rear armature bearing 1 already pressed onto the armature shaft prior to assembling the motor cover 47 to the tool
6. 170 3253 10 9170 3252 90 9170 4650 90 9170 4651 00 9170 4651 10 9170 4651 20 9170 4651 30 9170 4651 40 9170 4651 50 9170 3253 90 9170 4652 00 9170 3252 50 9170 4666 00 9170 4665 90 9170 4652 90 9170 4653 40 9170 4653 60 9170 4654 00 9170 4654 10 9170 4668 30 9170 4654 50 9170 4654 60 9170 4655 00 9170 4655 30 9170 4655 40 9170 4655 70 9170 4655 90 9170 4656 10 9170 4656 30 9170 4672 80 9170 4657 80 9170 4673 20 O Bearing Cup 100 e s A DESCRIPTION OF PART NO REO pl Ball Bearing j Vent Kit 46 Q Pivot Nut Pivot Bolt K50 x 8mm Pan Hd Plastite Screw K35 x 8mm Pan Hd Plastite Screw K60 x 20mm Pan Hd Plastite Screw K60 x 40mm Pan Hd Plastite Screw K50 x 30mm Pan Hd PT DG Screw K60 x 18mm Pan Hd PT DG Screw K60 x 120mm Pan Hd PT DG Screw Pan Hd Cap Screw Slotted Plastite Torx Screw K50 x 18mm Pan Hd Plastite Screw Thumbwheel Service Nameplate Kit Electronics Assembly Armature Kit See Service Note Field Brush Card Assembly Blade Housing Assembly Quik Lok Cord Set Switch Crankcase Assembly Upper Handle Mount Module Cover Motor Cover Left Handle Half Right Handle Half Motor Housing Armature Service Note s When servicing the armature i use Armature Kit No 9170 4653 40 If the tool has a spacer in the armature bearing bore of the gearcase remove the 93 9170 4666 10 Brush Spring 94 9170 4660 80 Bellows Rear Shroud 96 9170 4654 90 Light Pipe
7. IRING SERVICE MECHANISK MOTOR BURNT MMII F OUT MACHIHE OK
8. Vent Kit 100 9170 4661 40 Cushion Grip O Ring 122 9170 325400 Rubber Washer N S oo oo oo si st ao of hb DD PN YN PO PNY D HH AH HH SH SH Tatra en a i a e e E Y e e a e E e E e Y eher e a ee a ee Su a ee ET ee ar DN a E Oe cs DN ee a ka ee gt A A Nee rr rr rr a a a o oo e e e e e e e gt e e e e A e A A A A 123 9170466280 Handle Seal 95 9170325430 Isolation Module Assembly A SEE PAGE 5 FOR ADDITIONAL LUBRICATION AND SERVICE NOTES spacer and install O Ring No 9170 4673 00 into the empty groove The O Ring is provided in the kit FIG PART NO DESCRIPTION OF PART NO REO 92 9170 4653 80 Carbon Brush Kit Includes 2 Brushes Service and Repair Manual Model 840M A SEE PAGE 5 FOR ADDITIONAL LUBRICATION AND SERVICE NOTES e 9170 4672 00 HAMMER SERVICE KIT THIS KIT CONTAINS 9170 4672 10 9170 4672 20 9170 4664 70 9170 4653 80 CARBON BRUSH SERVICE KIT THIS KIT CONTAINS Carbon Brush Carbon Brush 2 9170465510 Cap Plug 1 9170465740 Gearcase Seal 2 9170325550 O Ring 1 91704657 70 Cap Seal 1 9170465800 O Ring 1 9170465820 O Ring 1 9170467300 O Ring 1 9170465830 Damping Washer 1 9170467320 Bearing Cup 2 9170466320 Split Sleeve 4 4 4 S2 Grease 7 oz Tube Carbon Brush 103 65 64 119 18 71 119 Chamfer for barrel washers 119 are to face to the outside as shown Do not wash clutch gear assembly 57 If
9. er 72 91703257 80 External Retaining Ring 73 9170465860 Retaining Ring 74 91704658 70 Spindle 75 9170465900 Shift Spring 76 9170465910 Compression Spring 80 9170325930 Key Spring 81 9170 325880 Side Handle Band 84 9170325850 Chuck Collar 8 9170325870 Collar 87 9170466030 Barrel 88 9170466650 Shift Disk Assembly 89 9170466050 Spring Flange 90 9170325770 Side Handle Assembly 97 9170325910 Keys 98 9170465310 Shift Knob Assembly 101 9170466160 Wrist Pin 102 91704661 70 Piston 103 9170 4661 80 Ram 104 9170 325920 Key Retaining Ring 105 9170 325820 Band Retainer 106 9170 325840 Seal Retaining Ring 107 9170 4662 20 Shift Ring 108 9170 3257 60 Depth Gauge Rod 109 9170 3255 10 Connecting Rod Assembly 111 9170 325830 Dust Seal 112 91704663 10 Felt Seal 113 Spindle Seal 114 9170 466330 Retaining Slug 115 9170 466360 SDS Max Striker 118 9170466400 Washer 119 9170 4664 10 Barrel Washer 121 9170 466430 Washer 124 9170 3257 90 Wave Washer 125 9170 467280 Vent Kit NOTE Check the clutch torque Clutch must slip at 40 to 50 ft lbs at the spindle checked clockwise as viewed from the front of the tool Press Needle Bearing 7 gt 016 Ref in Connecting Rod 109 Both sides so that the same amount sticks out on both sides of the Rod Nd OSA Press Needle Bearing 6 into Crankcase 37 flush with the top of the crankcase casting as shown
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