Kango 845K Installation and operating manual

Part. No. 55-24-3925
845K
GB

Service and Repair Manual
Model 845K 2
WARRANTY AND LIABILITY STATEMENT
All repairs may be completed with standard workshop tools and equipment.
SERVICE TOOLS
se only Authorized parts. Any damage or malfunction caused by the use of unauthorized parts
is not covered by Warranty or Product Liability.
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, G EASE O OTHE PA TS DEEMED NECESSA Y FO SE VICING A E IN THE SE VICE KIT.
ALL NEEDLE OLLE BEA INGS SHOULD BE P ESSED WITH THE OUNDED EDGE ENTE ING THE BO E FI ST, AND THE P ESS TOOL
P ESSING AGAINST THE FLAT SU FACE OF THE BEA ING.
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. P ECAUTIONS MUST BE TAKEN FO PE SONAL SAFETY THE USE OF EYE P OTECTION AND
GLOVES IS ECOMMENDED.
Inspection
All mechanical and electric parts should be inspected for wear and replaced as required.

3
Service and Repair Manual
Model 845K
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
40 22-64-0679 Cord Set (1)
41 23-52-1550 Brush Spring (2)
42 23-66-2750 Speed Control Switch (1)
47 28-90-0280 Upper Handle Mount (1)
50 31-15-0432 Motor Cover (1)
51 31-44-1984 Left Handle Half (1)
52 31-44-1963 ight Handle Half (1)
53 31-50-0533 Motor Housing (1)
54 31-55-0243 Left Shroud (1)
55 31-55-0253 ight Shroud (1)
56 31-55-0220 Belly Shroud (1)
59 34-60-3620 etaining ing (1)
62 34-40-4160 O- ing (1)
76 34-60-3630 etaining ing (1)
77 40-50-8585 Torsion Spring (1)
79 40-50-8690 Compression Spring (2)
80 42-96-0130 Bearing Cup (1)
82 43-06-0690 Shift Disk (1)
87 43-87-0030 Isolation Bellows (1)
88 43-87-0040 Pivot Isolator (2)
89 43-87-0060 Isolation Module Assembly (1)
90 43-98-0470 otostop Knob (1)
92 14-46-1001 Foam Slug Kit (Bag of 10) (1)
93 44-52-0580 Handle Cushion (1)
110 45-88-8555 ubber Washer (2)
114 22-84-0875 Fan (1)
123 44-76-0210 Cord Protector (1)
124 --------------- Inductor Boat (Incl. with Fig. 31) (1)
%SEE PAGE 5 FOR
ADDITIONAL LUBRICATION
AND SERVICE NOTES
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
2 02-02-1300 5 mm Steel Ball (2)
4 02-04-0847 Ball Bearing (1)
7 02-04-1518 Ball Bearing (1)
13 05-59-0100 Pivot Nut (1)
15 05-77-0100 Pivot Bolt (1)
16 05-81-0920 M6 x 1.0 x 120 Pan Hd. Slt. Tapt. T-27 (4)
19 06-81-1805 Special Screw (2)
20 06-82-7252 8-32 x 3/8" Pan Hd. Slt. Tapt. T-20 (4)
21 06-82-7425 8-16 x 2" Pan Hd. Slt. Plast. T-20 (2)
24 06-95-6290 M5 x 2.24 x 18 Pan Hd. Slt. PT T-20 (7)
25 06-65-3720 Dowel Pin-Knurled (1)
26 10-75-2740 ound Label (1)
31 14-20-0845 110 V Electronics Assembly (1)
32 16-50-0045 110 Volt Armature (1)
33 18-50-0045 110 Volt Field (1)
34 22-18-0811 110 V Carbon Brush (2)
36 22-22-1480 Brush Carrier Assembly (1)
39A 31-17-0260 Lower Cord Clamp (1)
39B 31-17-0265 Upper Cord Clamp
l
EXAMPLE:
Component Parts (Small #) Are Included
When Ordering The Assembly (Large #).
0
00

Service and Repair Manual
Model 845K 4
Assemble Thrust Washers
#107 and Belleville Spring
Washers #78 into Intermediate
Housing #46 as illustrated.
NOTE: SE OIL
ON ALL AREAS
TO BE PRESS FIT
%SEE PAGE 5
FOR ADDITIONAL
LUBRICATION
AND SERVICE NOTES
l 14-46-9300 HAMMER SERVICE KIT
THIS KIT CONTAINS:
1 31-12-0270 Cap-Cover
1 34-40-4310 ubber Damping Washer
1 34-40-4320 Seal-Cover
1 34-40-4330 O- ing
1 34-40-4350 O- ing
1 34-40-0045 Cap Seal
1 34-40-0046 O- ing
1 34-40-4470 O- ing
1 42-96-0130 Bearing Cup
1 43-44-0970 Gasket
1 45-06-0545 Dust Seal
1 51-08-5235 6 Oz. Tube "S" Grease
_______________________________________________________________
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FASTENER TORQ E SPECIFICATIONS (IN./LBS.)
SEATING TORQ E
FIG. NO. MINIM M MAXIM M
14 120 140
15 20 25
16 30 35
19 30 35
20 25 30
21 20 25
22 25 30
25 30
20 25
610
25 35 45
105 60 70
HANDLE HALVES
AND SHROUDS
CUSHION GRIP
CRANKCASE COVER
23
24

5
Service and Repair Manual
Model 845K
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 02-02-0120 1/8" Steel Ball (12)
3 02-02-0250 1/4" Steel Ball (1)
5 02-04-0911 Ball Bearing (1)
6 02-04-1510 Ball Bearing (1)
8 02-04-2000 Ball Bearing (1)
9 02-50-2470 Needle Bearing (3)
10 02-50-4020 Needle Bearing (1)
11 02-50-9000 Needle Bearing (1)
12 02-50-9985 Needle Bearing (1)
14 05-74-0670 M6 x 1.0 x 70 Skt. Hd. Cap Screw T-27 (4)
17 06-65-0827 Cross Pin (1)
18 06-65-1660 Dowel Pin (1)
22 06-82-8842 8-32 x 3/8" Pan Hd. Slt. Taptite T-20 (1)
23 06-95-6280 M4 x 0.7 x 14 Pan Hd. Slt. Taptite T-20 (4)
28 34-60-2580 External etaining ing (1)
43 30-89-0010 Bearing etainer (1)
44 28-14-2297 Crankcase (1)
45 28-20-1325 Crankcase Cover (1)
46 28-50-6445 Intermediate Housing (1)
48 14-52-0040 Nose Assembly (1)
49 31-12-0270 Cap-Cover (1)
57 32-05-2250 Bevel Gear (1)
58 34-40-0045 Cap Seal (1)
60 34-40-0046 O- ing (1)
61 34-40-1375 O- ing (1)
63 34-40-4310 ubber Damping Washer (1)
64 34-40-4320 Seal-Cover (1)
65 34-40-4330 O- ing (1)
66 34-40-4350 O- ing (1)
67 34-40-4470 O- ing (1)
68 34-60-0700 etaining ing (1)
69 34-80-5090 etaining ing-Beveled (1)
70 36-14-0790 Clutch Shaft (1)
71 36-14-0770 Hollow Clutch Shaft (1)
72 14-09-0140 Crankshaft Assembly (1)
73 38-50-6265 Spindle (1)
74 40-50-8420 Bit Lock Spring (1)
75 40-50-8575 Compression Spring (1)
78 40-50-8590 Belleville Spring (2)
81 42-98-0300 Barrel (1)
83 43-34-0740 Spring Flange (1)
84 43-44-0970 Gasket (1)
91 44-20-0322 Bit Lock (1)
94 44-60-1710 Wrist Pin (1)
95 44-62-0220 Piston (1)
96 44-66-6030 Splined Clutch Plate (1)
97 44-66-6045 Fixed Clutch Plate (1)
98 44-82-0225 am (1)
99 44-90-4400 Shift ing (1)
100 44-94-0395 Connecting od Assembly (1)
101 45-06-0545 Dust Seal-Hex (1)
102 45-06-0046 Oil Seal (1)
104 45-56-2610 Striker (1)
105 06-82-8872 DG50 x 16mm Torx Pan Head Screw (4)
106 45-06-0045 Felt Seal (2)
107 45-88-8520 Thrust Washer (2)
108 45-88-8530 Barrel Thrust Washer (1)
109 45-88-8535 Striker Cushion Washer (1)
113 45-88-8730 Wave Washer (1)
115 06-14-0065 Hex Head Bolt-Special (1)
116 42-16-0125 Side Handle Band (1)
117 14-34-0516 Side Handle Assembly (1)
118 14-34-0551 Depth od Mount Assembly (1)
119 44-94-0165 Depth Gauge od (1)
120 44-86-0620 Band etainer (1)
121 31-44-2000 Side Handle Housing (1)
NOTE: Check the clutch torque. Clutch must slip at 35 to 45 ft.lbs.
at the spindle, checked clockwise as viewed from the front
of the tool.
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LUBRICATION NOTES: (TYPE "S" GREASE, NO. 51-08-5235
Fill Piston #95 with grease and
assemble to Connecting od #100
with Wrist Pin #94. Front surface
of Piston to be free of grease.
Lubricate O- ing #67
with grease.
Place 1.5 oz. grease here.
Place a total of 1.0 oz. grease
in the barrel cavity in the crankcase #44.
Place .5 oz. in each corner in barrel
chamber.
Apply grease to
spline surface #71.
Apply grease
to lobed
surface #97. Apply grease to
lobed surface #96.
Apply grease to radius
and spline surface #70.
Apply .5 oz. grease on clutch
assembly, filling the spring coils.
Lightly grease
Spring #74 and
bit lock #91.
Place .5 oz. grease in
lower clutch pinion cavity.
Seal to be installed with
garter spring to left as shown.
F ONT OF C ANKCASE
Spacer
(5311 only)
Place
1.5 oz.
grease in bottom
of crankcase prior to
installing crankshaft
assembly.
Dip Felt Washers #106 into light oil.
Press Oil Seal #102 and Felt Washers
into Nose #48 to dimension shown.
1.5+/-.015
Lubricate O- ing with grease.
Install O- ing onto am.
Assemble Cap Seal onto am.
esize Cap Seal and load into
Barrel (seal end first). am
should be located flush with
end of Barrel.

Service and Repair Manual
Model 845K 6
FIG. %NOTES
54, 55, 56 TO REMOVE BELLY SHROUD #56 FROM TOOL, INSERT SMALL SCREW
DRIVER INTO GROOVE BETWEEN BELLY AND 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.
54, 55 TO INSTALL THE SIDE SHROUDS #54 AND #55, THE TOP HINGE OF THE
SHROUDS MUST BE COMPLETELY INTERLOC ED, THEN THE BAC SIDE
ROTATED CLOSED AROUND THE TOOL.
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 STRI ER CUSHION WASHER #109 WITH A MEDIUM
COATING OF GREASE BEFORE ASSEMBLY.
10, 100 PRESS NEEDLE BEARING #10 IN ROD #100 SO THAT THE SAME AMOUNT
STIC S 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 PRESS NEEDLE BEARINGS #11 AND #12 FLUSH TO THE MACHINED
FACES ON BOTH ENDS OF THE INTERMEDIATE HOUSING #46.
9, 44 PRESS NEEDLE BEARING #9 INTO CRAN CASE #44, FLUSH WITH TOP
OF BORE, AS SHOWN.
81 LIGHTLY GREASE INSIDE OF BARREL #81 BEFORE ASSEMBLY.
48, 73 SMALL OUTSIDE DIAMETER OF SPINDLE #73 IS TO BE LUBRICATED
WITH A LIGHT COAT OF GREASE BEFORE ASSEMBLING THE NOSE
ASSEMBLY #48 TO THE TOOL.
48, 73, 102 NOSE ASSEMBLY #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
BLUE LOCTITE.
48, 102 LUBRICATE BORE IN 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 SNAP RING #69 WITH BEVEL SIDE UP.
4, 50, 80 PLACE BEARING CUP #80 ON SMALL ARMATURE BEARING #4 BEFORE
INSTALLING MOTOR COVER #50.
41 BRUSH SPRINGS #41 ARE TO BE WOUND 1/2 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
CRAN CASE, MA E SURE SCREW IS STARTED IN EXISTING THREAD.
DO NOT CREATE TWO SETS OF THREADS IN ONE HOLE.

7
Service and Repair Manual
Model 845K
Wire Color
WIRING
SCHEMATIC
Inductor Boat
Wire Origin or
No. 110 V 120 V 230 V Part No. Connection
1 Blue White Blue Cord Switch
2 Brown Black Brown Cord Switch
3 ed ed ed Field Lead 9
4 ed ed ed Field Switch
5 Yellow Yellow Yellow Field Brush Holder
6 Black Black Black Field Brush Holder
7 White White White Motor Control Assy. Switch
8 Black Black Black Motor Control Assy. Switch
9 Black Blue ed Motor Control Assy. Lead 3
Tuck all wiring into left handle half
prior to assembling right handle half.
This will avoid pinched wires.
Wrap
wire tie around
electronics boat
to retain leads as
shown.
Cord to
be inserted into clamp
trap. Cord to extend 1/4"
minimum above top of
clamp. (For 120 V only.
See below for 110 V
and 230 V.)
Fast-on
terminals must be
completely connected
between leads 4 and 9.
Keep leads
away from
potential
pinch points.
Electronics Assembly
WIRING SPECIFICATIONS
SWITCH
CONNECTIONS
(Bottom view)
Tuck leads
5 and 6
away from
armature.
BR SH CARD
ASSEMBLY
Brush to
brush plate
connections.
Brush shunt wires to
be positioned up in
brush tube slots, as
shown, for full travel.
Check that there is
clearance between the
fan and brush shunt
wires.
Brush
springs
must be seated
in slot located on
brush tubes.
As an aid to reassembly, take note of wire routing and
position in wire guides and traps while dismantling tool.
110 V and 230 V
Q IK-LOK CORD
ORIENTATION

Service and Repair Manual
Model 845K 8
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)
AArmature shaft to lamination pack 1500 Volts (min)
BLamination pack to commutator 1200 Volts (min)
CArmatuure shaft to commutator 3000 Volts (min)
ELECTRICAL PERFORMANCE TEST READINGS
CLUTCH SLIP
Measured on disassembly/assembly 35/45ft lbs 47/61Nm. (Non Electrical Test)
Note: On all test readings + or -5% of figures shown is acceptable.
845K
845K
MODEL 110V 120V 220V-240V
ARMATURES
.440/.506 Ohms .440/.506 Ohms 1.283/1.477 Ohms
FIELD COILS
845K
110V 120V 220V-240V
4.5/6.5 Amps 4.5/6.5 Amps 2.9/4.4 Amps
.349/.401 Ohms .349/.401 Ohms 1.339/1.54 Ohms
PERFORMANCE
110V 120V 220V-240V
Running No Lo d

9
Service and Repair Manual
Model 845K
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.
2. The full voltage of 4000 volts should be maintained without breakdown or flashover for a few seconds.
3. 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.
With the aid of the Fault Finding chart (below) the source of any malfunction may be quickly identified and repaired.
FAULT FINDING

55-24-3925d1 7/01 Printed in U.S.A.
Atlas Copco Berema AB Sickla Industriväg 1A S-105 23
Nacka Stockholm
Telephone: [phone] Fax: [phone]