Kango 810 Installation and operating manual

6
Service and Repair Manual
Model 810V
TORQUE SETTINGS
SERVICETOOLS
MODEL 810
ITEM NO. PART NO. IN/LBS. NM
102 9170 3250 10 28 3
111 9170 3251 00 33 4
120 9170 3251 90 23 2.5
126/128 9170 3252 50 18 2
126/127 9170 3252 50 8 1
130 9170 3252 90 23 2.5
132 9170 3253 10 23 2.5
140 9170 3253 90 33 4
203 9170 3254 60 23 2.5
204 9170 3254 70 28 3
216 9170 3261 90 23 2.5
247 9170 3258 90 130 16
272 9170 3254 70 33 4
All repairs may be completed with standard workshop tools and equipment.

7
Service and Repair Manual
Model 810V
DISMANTLING
Important! Before carrying out any repairs, the saw should be checked for electrical safety and for mechanical
performance. For electrical safety the saw 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. The saw should then be checked by high voltage flash testing. On completion
of dismantling procedure all electrical components should then be checked for electrical safety. The saw
should ONLY be functionally checked if the unit passes the electrical safety test.
Removing the
belly shroud
1. Remove four screws (102) and the belly shroud
(101)
(tap off using small screwdriver).
2. Remove O-ring (109) and circlip (108).
3. Remove following items:
- rotostop knob assembly (103)
- two balls (105)
- two compression springs (104)
4. Remove following items:
- shift disk assembly (107)
- torsion spring (106)
Dismantling
the armature
assembly
1. Remove bearing cup (112) and bearing (113).
2. Remove fan (115).
3. Remove bearing (117) and retaining ring (116).
Removing the
armature
1. Remove four screws (111) and the
motor cover (110).
2. Disconnect two wires, release retaining clip and
remove brush carrier assembly (121).
3. Remove armature assembly (114).
109
108
105
107
101
118
121
114
110
111
117
116
114
115
113
112
102
106
103
104
Fig. 1
Fig. 2
Fig. 3

8
Service and Repair Manual
Model 810V
Dismantling
the brush
carrier
assembly
1. Remove two carbon brushes (123).
2. Remove two springs (122). 122
121
123
123
Removing
the handle
assembly 127
126
126
132
126
128
135
136
131
131
134
130
129
126
126
1. Remove screw (126) and handle
cushion (127).
2. Remove pivot bolt (130) and pivot nut (132).
3. Remove handle halves (128), (129) and two pivot
isolators (131).
4. Remove switch wires from handle half (129).
5. Remove lower cord clamp (135), upper cord
clamp (136) and foam slug (134).
1. Remove cord (138) and cord protector (139).
2. Remove speed control (133) and switch (137).
Removing
the speed
control
switch 137
133
138
139
Fig. 4
Fig. 5
Fig. 6

9
Service and Repair Manual
Model 810V
Removing
the isolation
module
assembly
125
124
126
Removing
the side
shroulds
1. Remove two screws (126).
2. Remove side shrouds (124) and (125).
1. Push back chuck collar (243), push back retaining
ring (242) and remove dust seal (241).
2. Remove chuck collar (243), spacer (244) and
collar (245) and retaining ring (242).
Removing the
chuck collar
126
144 143
142
140
141
242 244 245
243
241
1. Remove two bolts (140) and two washers (141).
2. Remove upper handle mount (142), isolations
bellows (143) and isolation module (144).
WARNING: Do not disassemble isolation module
(144).
Removing
the field
assembly
1. Remove field coil leads from switch
(137).
2. Remove two screws (120) and field
(119) from the motor housing (118). 120
118
119
Fig. 7
Fig. 8
Fig. 9
Fig. 10

10
Service and Repair Manual
Model 810V
Removing the
side handle
assembly
1. Remove depth gauge (234) and mount (233) (if
fitted).
2. Remove handle (235), circlip (236) and washer
(237).
3. Remove housing (238).
4. Remove pin (239), retainer (240) and handle band
(246).
Removing the
intermediate
housing
1. Remove four bolts (247) and nose
flange (257).
2. Push back retainer (250) and remove two keys
(249).
3. Remove the following items:
- retainer (250)
- spring (251)
- circlip (252)
- spring flange (253)
- felt seal (254)
4. Remove intermediate housing assembly (257),
remove spindle assembly from intermediate housing
(257) and gasket (274).
204
207
275
201
202
Removing
the crank-
case top
cover
1. Remove cap (202), screw (203), four screws (204),
cover (201) and seal (207).
2. Remove clip (205) and bearing (206).
Note: To remove the screw (203) it will be necessary
to lock the crank gear (213).
233
234
239
237
235 236
240
238
246
274
257
275
253
252 254
247
257
250 249
251
Spindle
Assembly
203
205
206
Fig. 11
Fig. 12
Fig. 13

11
Service and Repair Manual
Model 810V
Dismantling
the barrel
assembly
1. Remove two screws (272) and barrel (273).
2. Remove the following items:
- ram (271)
- O-ring (266)
Dismantling
the spindle
assembly
Dismantling
the clutch
assembly
1. Remove oilseal (254) from intermediate housing
(257).
2. Remove circlip (256).
3. Press out the following items:
- bearing (258)
- thrust washer (259)
- four belleville springs (260)
- thrust washer (259)
- bearing (261)
4. Remove four drive pins (264).
5. Remove the following items:
- spindle extension (262)
- O-ring (263)
- O-ring (266)
- striker (267)
- cushion washer (268)
- damping washer (269)
- thrust washer (270)
1. Remove two screws (216), bearing retainer (217)
and clutch tube (218).
Note: Note the position of selector hole in clutch
tube (218).
2. Remove retaining clip (232), remove hollow
clutch shaft assembly (229) and press off bearing
(230) and bevel gear (231), remove bearings (228)
from hollow clutch shaft (229).
3. Remove spring flange (227), spring (226), splined
clutch plate (225), fixed clutch plate (224), 12
steel balls (223) and shift ring (222).
4. Press off bearing (220) and clutch pinion (219).
261
259
259
258
256
263 264
260
265
262
273
266
275
271 272
228
216
222
229
217
223
228
218
224 230
219
225
231
232
226
220
275
221
227
254
257
266267268
269270
Fig. 15
Fig. 16
Fig. 14

12
Service and Repair Manual
Model 810V
1. Remove screw (203), circlip (205) and bearing
(206).
2. Remove connecting rod assembly (208).
3. Remove crankshaft assembly (213) and needle
bearing assembly (214).
Dismantling
the crank
assembly
Dismantling
the
connecting
rod assembly
1. Press out bearing (209).
2. Remove gudgon pin (210), piston (211) and
O-ring (212).
209
208
210
211
212
203
206
208
214
205
213
Fig. 17
Fig. 18

13
Service and Repair Manual
Model 810V
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 occurring.
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 electrical parts should be inspected for wear and replaced as required.

14
Service and Repair Manual
Model 810V
Lubrication At service and repair intervals the lubrication should be carried out as shown in the diagram below. All
parts in the service kit should be fitted. The total amount of grease for the 810V is 5oz (125gm).
Lubrication of the hammer is as shown on the grease chart.
ALL SCREWS SHOULD BE REFITTED WITH LOCKTITE 271 OR SIMILAR
14gm
28gm
28gm
42.5gm
Smear Generously
Coat
Liberally
Coat Pack Type M grease
Type N grease

15
Service and Repair Manual
Model 810V
Electrical test Before assembly all electrical parts MUST be checked for safety, and that they conform to specification.
AArmature shaft to lamination pack 1500 Volts (min)
BLamination pack to commutator 1200 Volts (min)
CArmature shaft to commutator 3000 Volts (min)
ELECTRICALTESTING
ELECTRICALPERFORMANCETESTREADINGS
ARMATURES
MODEL 110V 120V 220V 240V
810V .697/723Ω .697/723Ω 2.87/2.89Ω 2.87/2.89Ω
FIELD COILS
110V 120V 220V 240V
810V .96Ω.96Ω3.705Ω3.705Ω
PERFORMANCE
Full Load Hammer Test
110V 120V 220V 240V
810V 875W 1020W 1020W 1020W
CLUTCH SLIP
Measured on disassembly/assembly 30/38ft lbs 40/51Nm. (Non Electical Test)
Testing the
Armature
(Flash
Testing)
Note:- On all test readings + or - 5% of figures shown is acceptable.
A
C
B

16
Service and Repair Manual
Model 810V
ASSEMBLY
1. Press bearing (209) into connecting
rod (208).
2. Position piston (211) and fit gudgon pin (210).
3. Refit O-ring (212).
Assembling
the connecting
rod assembly
1. Place crankcase (275) into vice, press needle
bearing assembly (214) into crankcase (275), refit
the crankshaft assembly (213).
2. Refit the connecting rod assembly (208), bearing
(206) and secure using screw (203) tighten to 23
in/lbs (2.5Nm) torque and circlip (205).
Caution: Use alloy jaw plates in the vice to
prevent damage to the crankcase (275).
Assembling
the crank
assembly
Assembling
the clutch
assembly
1. Refit the following items onto clutch shaft (221):-
- bearing (220)
- clutch pinion (219)
- shift ring (222)
- twelve steel bearings (223)
- fixed clutch plate (224)
- splined clutch plate (225)
- spring (226)
- spring flange (227)
2. Press needle bearing (228) in hollow clutch shaft
(229).
Caution: The two needle bearings (228) must be
fitted flush in hollow clutch shaft (229).
3. Press bearing (230) and bevel gear (231) onto
hollow clutch shaft (221).
4. Compress items assembled in step 1,2,3 and
secure using retaining ring (232).
5. Refit clutch tube (218) and refit clutch assembly
into the crankcase (275).
6. Refit bearing retainer (217) and secure using two
screws (216).
209
208
210
211
212
203
206
208
214
205
213
228
216
222
229
217
223
228
218
224 230
219
225
231
232
226
220
275
221
227
275
Fig. 19
Fig. 20
Fig. 21

17
Service and Repair Manual
Model 810V
Assembling
the spindle
assmbly
1. Refit O-ring (263) and fit spindle extension (262)
onto spindle (265), secure using four drive pins
(264).
2. Refit the following items onto intermediate housing
(257):
- bearing (261)
- thrust washer (259)
- four belleville springs (260)
- thrust washer (259)
- bearing (258)
- circlip (256)
- seal (254)
3. Fit the following items into spindle assembly (265):
- O-ring (266)
- ram (271)
- thrust washer (270)
- damping washer (269)
- cushion washer (268)
4. Fit spindle assembly into intermediate housing (254)
and fit the following items:
- stiker (267)
- O-ring (266)
1. Fit the barrel assembly into the crankcase (275)
and secure using two screws (272).
2. Fit O-ring (266) onto striker (271) and assemble
into barrel (273).
Assembling
the barrel
assembly
1. Fit bearing (205) in cap (206), fit circlip (205).
2. Fit seal (207), cover (201) and secure using four
screws (204) and screw (203).
3. Fit cap (202).
Refitting the
crankcase
top cover
273
266
275
271 272
261
259
259
258
256
263 264
260
265
262
204
207
201
202
275
203
205
206
254
257
266
270
269
268
267
Fig. 22
Fig. 23
Fig. 24

18
Service and Repair Manual
Model 810V
Refitting the
intermediate
housing
1. Refit the spindle assembly, gasket (274) and
intermediate housing (257) to the crank case
(275).
2. Refit the following items:
- felt seal (254)
- spring flange (253)
and secure using circlip (252).
3. Refit spring (251) and retainer (250), secure using
two keys (249).
4. Refit nose flange (257) secure using four bolts
(247) tighten to 130 in/lbs (16Nm) torque.
Refitting the
side handle
assembly
1. Fit handle band (246), retainer (240) and secure
using pin (239).
2. Fit housing (238), washer (237) secure using
circlip (236).
3. Fit handle (235).
4. Fit mount (233) and depth gauge (234).
1. Fit collar (245), spacer (244) and chuck collar
(243) and secure using retaining ring (242).
2. Fit dust seal (241).
Assembling
the chuck
collar
274
257
275
253
252 254
247
257
250 249
251
233
234
239
237
235 236
240
238
246
242 244 245
243
241
Spindle
Assembly
Fig. 25
Fig. 26
Fig. 27

19
Service and Repair Manual
Model 810V
1. Fit the two side shrouds (124), (125) and secure
using two screws (126).
Note: ensure correct location over the isolation
bellows (143).
Refitting the
side shrouds
Assembling
the field
assembly
1. Fit field (119) into motor housing (118) and
secure using two screws (120), tighten to 23 in/
lbs (2.5Nm) torque.
2. Fit the motor housing to crank case (275).
Refitting the
speed control
switch
1. Fit the speed controller (133) and switch (137)
into the handle half (129).
2. Connect the cord (138) and fit cord protector
(139).
Refitting the
isolation
module
assembly
1. Fit the isolation module (144), isolation bellows
(143) and upper handle mount (142), secure using
two washers (141) and two bolts (140), tighten to
33 in/lbs torque (4Nm).
144 143
142
140
141
125
124
126
126
120
118
119
137
133 138
139
129
Fig. 28
Fig. 29
Fig. 30
Fig. 31

20
Service and Repair Manual
Model 810V
Assembling
the armature
assemmbly
1. Fit retaining ring (116) and bearing (117).
2. Fit fan (115), bearing (113) and bearing cap
(112).
1. Fit two springs (122) and carbon brushes (123).
Connect brush leads.
Assembling
the brush
carrier
1. Fit cord clamps (135) and (136).
2. Correctly route the wires and secure using foam
slug (134).
3. Fit two pivot isolators (131) to the field housing
assembly (118).
4. Assemble two handle halves (128), (129) and
secure to isolation module assembly and motor
housing (118) using four screws (126), tighten to
18 in/lbs (2Nm) torque, pivot bolt (130) and
pivot nut (132), tighten to 23 in/lbs (2.5Nm)
torque.
5. Fit handle cushion (127) and secure using screw
(126).
Assembling
the handle
assembly 127
126
126
132
126
128
135
136
131
131
134
130
129
126
126
122
121
123
123
117
116
114
115
113
112
Fig. 32
Fig. 33
Fig. 34

21
Service and Repair Manual
Model 810V
Fitting the
armature
assembly
1. Fit armature assembly (114).
2. Fit brush carrier (121) and connect two wires.
3. Fit motor cover (110) and secure using four
screws (111), tighten to 33 in/lbs (4Nm) torque.
Note: Ensure the brush carrier (121) is fitted the
correct way (brushes (123) facing down,
towards the motor cover (110)).
1. Fit the following items onto the belly shroud
(101):
- shift disk assembly (107)
- torsion spring (106)
- two compression springs (104)
- two balls (105)
2. Fit rotostop knob assembly (103).
3. Fit O-ring (109) and secure rotostop knob
assembly (103) using circlip (108).
4. Fit belly shroud (101) to the tool and secure using
four screws (102), tighten to 28 in/lbs (3Nm)
torque.
Note: Roto stop assembly (103) must be in the
centre position to locate into crankcase
(275).
Assembling
the belly
shroud
118
121
114
110
111
109
108
105
107
101 102
106
103
104
Fig. 35
Fig. 36

22
Service and Repair Manual
Model 810V
FAULT FINDING
REMEDY FAULT
AND RETEST
MOTOR
REVOLVES?
MACHINE
HAMMERS?
MACHINE
IDLES?
SUPPLY
OK?
PLUG FUSE
OK?
BRUSHES
OK?
CORD
OK?
SWITCH
OK?
ARMATURE FIELD INTERNAL
WIRING
SERVICE
MECHANISM
MODULE
WAS MOTOR
BURNT OUT?
MACHINE
OK
YES
NO NO
YES
YES YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
With the aid of the Fault Finding chart (below) the source of any malfunction may be quickly identified and repaired.
LETHAL VOLTAGES PRESENT!!
On completion of the assembly, the unit must be flash tested at 4000 volts.
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.
2. The full voltage of 4000 volts should be maintained without breakdown or flashover for a few sec-
onds.
3. If the armature has been tested, remove the carbon brushes before carrying out the test, (thus
avoiding over-stressing the armature insulation system.)
4. The test voltage must be applied between the main casting and each live pin of the plug in succes-
sion.
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.
WARNING
Important
Flash Test
Running Test