Kango 900 Installation and operating manual

12
Service and Repair Manual
Model 900/950/990
ServiceTools
ITEM PART NO. DESCRIPTION
1 9170 0231 30 LONG ALLEN KEY
2 9170 0737 20 3/32 PIN PUNCH
3 9170 0231 40 SHORT ALLEN KEY
4 9170 0230 70 ALLEN KEY SET
5 9170 0239 10 SCREWDRIVER
6 9170 0231 50 TOP BEARING PULLER
7 9170 0232 40 BEARING ASSY TOOL
8 9170 0232 10 CARTRIDGE EJECTOR
9 9170 0232 20 EJECTOR BASE
10 9170 0236 40 WOOD BLOCKS
11 9170 0236 80 GREASE GUN
12 9170 0231 70 MTR DISMANTLING TOOL
13 9170 0232 00 FAN SPANNER
14 9170 0232 30 PINION MASK
15 9170 0233 20 5/8" COLLAR
16 9170 0233 50 BORE SUPPORT BAR
ITEM PART NO. DESCRIPTION
17 9170 0232 50 ROCKER PIVOT DRIFT
18 9170 0236 30 PINION NUT
19 9170 0233 00 DISC BEARING MANDREL
20 9170 0233 30 1 1/2" COLLAR
21 9170 0233 60 D/SHFT BRG MANDREL
22 9170 0232 60 ALIGNMENT BAR
23 9170 0234 10 BIG END BGR MANDREL
24 9170 3199 50 DUMMY HAMMER CASE
25 9170 0234 30 BIG END BGR EJECTOR
26 9170 0233 10 DISC MANDREL BASE
27 9170 0233 40 DISC BRG EJECT COLLAR
28 9170 0233 70 D/SHFT EJECTOR PUNCH
29 9170 0234 20 B/E BRG MANDREL BASE
30 9170 0233 80 CLUTCH BRG MANDREL
31 9170 0233 90 CLUTCH BRG MAN. BASE
32 9170 0234 40 CLUTCH TAIL MANDREL
ITEM PART NO. DESCRIPTION
33 9170 0234 60 CLUTCH TAIL EJECT BUSH
34 9170 0234 00 CLUTCH SHFT BGR BOLS
35 9170 0234 60 SHAFT BRG MAND. BASE
36 9170 0232 90 CLUTCH SPANNER
37 9170 0734 80 BRG DISMANTLING TOOL
38 9170 7327 01 BRG SERVICE TOOL
39 9170 0737 60 ADAPTOR, ALLEN KEY
40 9170 0236 70 SOCKETS - 3/8", 9/16"
41 9170 7327 02 BRG SERVICE TOOL
42 9170 7327 03 BRG SERVICE TOOL
43 9170 0737 90 CLUTCH TORQUE SET RIG
44 9170 0236 60 TORQUE WRENCH
1
2
3
45
67
8
9
10
11
12
13 14
17
22
18
23
19
15
20
16
21
22
24
30
31
32
33
29
25 26 27
36
37 38
34
35
39
43
40
44
41 42

13
Service and Repair Manual
Model 900/950/990
DISMANTLING
360
249
362
251
359
248
363
252
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. The hammer 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 hammer should ONLY be checked for hammer performance if the unit passes the
electrical safety test.
Note: In the disassembly instructions numbers
starting 200 are Model 900, numbers starting
with 300 are Model 950, numbers starting
with 400 are Model 990, numbers starting
with 500 are Model 900M in both text and
illustrations.
1. Remove knob (460), washer (459) and bolt (457).
2. Remove handle (458) and strap casing (456).
Removing
the forward
handle
(All models,
950 shown)
1. Using a suitable drift on the latch bar remove the
latch retainer (360, 245,), latch spring (363, 252),
latch spring cover (362, 251) and latch bar (359,
248).
Removing the
latch bar
mechanism.
(All models -
950S shown
except 900M)
Fig. 2
Fig. 1
Removing the
nosepiece.
(All models -
950S shown
except 900M)
1. Remove the four screws (365, 246, 443) and four
spring washers (366, 245, 442) from nosepiece
(367, 247, 444). Note that the screws are secured
by Loctite.
2. Remove the nosepiece (367, 247, 444) and driver
sealing felt (368) or compression ring (244, 441)
- (Model 900 & 990 only).
368
244
441
367
247
444
366
245
442
365
246
443
Fig. 3
460 459 458
456 457

14
Service and Repair Manual
Model 900/950/990
1. Remove the six screws (349, 229), six spring
washers (350, 230) securing the transmitter
housing (369, 242) to the hammer casing (346,
228).
2. Using a soft faced hammer, loosen and remove
the transmitter assembly. The transmitter
assembly contains the anvil assembly and
associated components. Remove the anvil
assembly from the transmitter assembly and
(Model 900 only) the stepped ring (235).
3. Remove the rubber ring (355, 236). Pull the anvil
(357, 238), recoil transfer ring (356, 237) and the
two anvil rings (358,239 ) from the driver
housing (372). Remove the anvil rings and recoil
transfer ring from the anvil.
4. Remove junk ring (373, 240) from driver (372)
(Model 950) or anvil sleeve (Model 900) and
press out the driver bearing (371) from the
transmitter housing.
5. Model 950 only. Using service tool, part no.
9710732701, press the drive shaft bearing (374)
from the transmitter housing (using thick grease
or similar product).
Dismantling
the transmit-
ter housing
(All models,
950 shown) 235
355
236
356
237
357
238
358
239
373
240
371
372
349
229
350
230
346
228
374
369
242
Removing the
driver
(900MV)
1. Remove the six screws (551), nose piece (550),
four balls (552) and trans housing (541).
2. Remove the following items:
- ‘O’ ring (542)
- ‘O’ ring (535)
- seal (543)
- junk ring (544)
- seal (545)
- anvil (546)
- junk ring (547)
- ‘O’ ring (548)
- driver (549)
563
Fig. 4
Fig. 5
Fig. 6
Dismantling
the SDS
assembly
(900MV)
1. Remove end cap (563) and chuck cover (562).
2. Remove the following items:
- wire clip (561)
- buffer stop (560)
- buffer (559)
- SDS chuck (558)
3. Remove two latches (557) and remove the
following items:
- latch plate (556)
- spring (555)
- lock plate (554)
- lock chuck (553)
562
561
560
559
558
557
556
555
554
553
557
352
549
548
547
546
545
544
543
535
542
541
552
550
551

15
Service and Repair Manual
Model 900/950/990
354
233
375
234
Dismantling
the buffer
housing (All
models,
Model 950
shown)
1. Remove the buffer housing (354, 233) from the
hammer casing (346, 228).
2. Remove the gaskets (352, 231), (375, 234) and
buffer housing ring (353, 232) from the buffer
housing.
346
228
352
231
353
232
1. Position the tool vertically in the vice, using soft
metal jaw plates, with the hammer case
uppermost.
2. Remove the six screws (348, 227, 427, 527) and
washers (347, 226, 426, 526) securing the
hammer casing (346, 228, 428, 528) to the motor
casing (149). Using a soft-faced hammer, loosen
the hammer casing.
3. Holding the connecting rod (305, 205, 405,505)
carefully remove the hammer casing. Remove the
gasket (150).
150
149
Dismantling
the hammer
casing.
Dismantling
the piston (All
models, 950
shown)
1. Remove the striker (301, 201, 401, 501) from the
piston (303, 203, 403, 503).
2. Push the gudgeon pin (304, 204, 404, 504) from
the piston and remove the piston from the
connecting rod (305, 205, 405, 505).
3. Remove the two piston seals (302, 202, 402, 502)
from the piston.
345
(950
ONLY)
528
428
346
228
527
427
348
227
526
426
347
226
505
405
305
205
301
201
401
501
305
205
405
505
304
204
404
504
302,
202
402
502
303
203
403
503
Fig. 7
Fig. 8
Fig. 9

16
Service and Repair Manual
Model 900/950/990
1. Remove the retainer circlip (307, 207, 407, 507)
and crank pin washer (308, 208, 408, 508).
Remove the connecting rod (305, 205, 405, 505).
2. Press the big end bearing (309, 209, 409, 509)
from the connecting rod.
Removing the
connecting
rod (All
models, 950
shown)
309
209
409
509
307
207
407
507
305
205
405
505
308
208
408
508
Dismantling
the gear
carrier
assembly
(Model 950
only)
334
336 337 338
335
339
343
344
345
Removing the
gear carrier
assembly. (All
models, Model
950 shown)
1. Hold gear carrier in vice by base. Remove the
four screws (339), and remove the clutch shaft
bearing cap (338).
2. Using a suitable mandril, press out the clutch
shaft tail bearing (337) from the bearing cap.
3. Remove the two thrust washers (335) and the
thrust bearing (336) and shim (334) from the
clutch shaft. Pull the clutch assembly from the
gear carrier.
4. Remove the drive shaft (345) from the gear
carrier. Remove the drive shaft thrust race (343)
and drive shaft thrust bearing (344) from the
drive shaft.
1. Remove six screws (320, 220, 420, 520) and six
spring washers (319, 219, 419, 519) securing the
gear carrier assembly to the motor casing.
2. Remove the gear carrier assembly (318, 218, 418,
518).
CLUTCH
ASSEMBLY
318
218
418
518
320
220
420
520
319
219
419
519
Fig. 10
Fig. 11
Fig. 12

17
Service and Repair Manual
Model 900/950/990
12
12
Dismantling
the crank
disc. (Model
950 shown)
323
312
326
1. Remove the screw (321, 221, 421, 521), spring
washer (322, 222, 422, 522) and gear clamp plate
(323, 223, 423, 523).
2. Pull the gear (324) or bearing keeper (224, 424,
524) from the crank disc shaft. (Model 950 only)
Using pliers remove the gear key (326) from the
gear.
3. Remove the crank disc (311, 211, 411, 511), the
two thrust races (313, 213, 413, 513), thrust
bearing (314, 214, 414, 514) and shim (s) (315,
215, 415, 515) from the gear carrier. Remove the
thrust races, bearing and shims from the crank
disc shaft.
4. Remove the crank pin nut (312, 212, 412, 512),
screw (306, 206, 406, 506) and crank pin bush
(310, 210, 410, 510)
Note: The crank pin screw and nut have left-
hand threads.
522
422
222
411
511
211
516
415
215
412
512
212
413
513
213
414
514
214
(Model 900 &
990 shown)
321
322
315
336
313
521
421
221
525
425
225
524
424
224
523
423
223
510
410
210
310
306 311
517
417
217
516
416
216
324
1
1
1
1
506
406
206
342
340
317
316
325
Dismantling
the gear
carrier. (All
models,
Model 950
shown)
1. Fill the drive shaft bearing (342) with thick grease
or similar material and using a suitable mandril
press out the bearing. (Model 950 only)
2. Press out the crank disc front bearing (316),
bearing spacer (317) and crank disc rear bearing
(325) and (Model 950 only) the clutch head
bearing (342).
341 327 328 329 331 332
330
333
1. Position the clutch assembly horizontally in a
vice. Straighten the clutch lock washer (328)
using soft metal jaw plates.
2. Using a spanner unscrew the clutch nut (327)
3. Remove the clutch lock washer (328), the clutch
spring (329), the two clutch plates (330) and the
gear (331). Press out the bearing (332) from the
gear (331)
4. Insert a 3/16 in. Allen key into the clutch pinion
shaft (341) and remove from the clutch hub (333).
Dismantling
the clutch
(Model 950
only)
Fig. 13
Fig. 14
Fig. 15

18
Service and Repair Manual
Model 900/950/990
Dismantling
the brushes.
(All models)
1. Remove the two end cap springs (174) and two
outer brush caps (173).
2. Unscrew the two inner brush end caps (127) and
remove the two carbon brushes (128).
174
173 127
128
1. Remove the four screws (104) securing the handle
(118) to the motor case (149) and remove the handle.
2. Depress the rocker assembly (101) and remove the
plunger (121).
3. Using a screwdriver lever out the large and small
handle plugs (102 and 119).
4. Press out the rocker pivot pin (120) and remove the
rocker assembly (101).
5. Unscrew and remove the lock button assembly (103).
6. Remove the motor end plate assembly (105).
Remove, from the end plate assembly, the two
terminal pads (107).
7. Remove the following items:
- spring ring (111)
- thrust washer (110)
- spring washer (108)
- bearing (126)
- bearing insulator (112)
Removing the
rear handle
and motor
end plate (All
models)
102
103
115
120
105
121
122
110
108
106
107
101
117
118
119
123
125
165
159
164
155 158
153
152
160
169
168
167
166
124
162
163
154
1. Slacken the four captive screws (162) securing the
switch cover (163) and remove the cover and the
switch box seal (160).
2. Lift the switch (159), remove the cover and
disconnect the four electrical connections.
Remove the condenser (158).
3. Remove two screws (168) securing the cord guard
housing (167) and remove the housing and cord.
Remove the two screws (152) securing the cord
grip (153) and remove the grip. Pull the power
cord free.
4. Lever off the plunger abutment plate (124) and
remove the two springs (177), two push rods
(123) and the switch plate (125). Remove the
switching pad (165), switch (159), the four
terminal pads (164) and the switch cup (155).
5. Remove elbow connector (174) from motor
housing. Remove grommet (166). Remove liner
(154) from motor housing. Remove grommet
(172).
Dismantling
the switch
(All models)
177
172
Fig. 16
Fig. 17
Fig. 18
116
104
126
112
111

19
Service and Repair Manual
Model 900/950/990
1. Remove the terminal screws (130) and remove the
field connections.
2. Remove the the top bearing inner race (126) using
service tool No. 9170 0231 50 and lever off the
top bearing shroud (112).
3. Remove the brush housing, the two waved
washers (133) and the pressure ring (134).
Dismantling
the rear
armature
bearing and
brush ring
(All models)
126
112
134
133
130
Dismantling
the brush
holder
housing (All
models)
114
113
129
130
131
1. Remove the four retaining screws (113) and two
brush holder retaining straps (114).
2. Remove the brush holders (130).
3. Remove the two terminal housings (131).
Dismantling
the motor
(All models)
1. Remove the two cartridge locating screws (151).
2. Using two main assembly screws (348) fit the
motor dismantling tool to the motor case. Ensure
the two field coil switch leads are pulled back into
the motor case
3. Screw in knob of the motor dismantling tool and
push the motor assembly from the motor housing.
Field coil switch leads
Motor
assembly
151
Fig. 19
Fig. 20
Fig. 21

20
Service and Repair Manual
Model 900/950/990
Dismantling
the armature
assembly (All
models)
1. Fit the pinion nut service tool to the pinion (145).
CAUTION: During the following operation take
care to ensure the fan (138) is not damaged by the
vice jaws.
2. Mount the armature assembly and pinion in a
vice, between two pieces of wood, with the pinion
nut uppermost. Using a suitable open-ended
spanner on the pinion nut unscrew the pinion
(145).
3. Pull the pinion bearing cartridge (175) from the
motor shaft. Remove the clip (179) and bearing
(141).
145
137
175
138
141
179
Fig. 22

21
Service and Repair Manual
Model 900/950/990
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 INSERTION 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.
Lubrication At service and repair intervals the lubrication should be carried out as shown in the diagram below.
(950 model) All parts in the service kit should be fitted. The total amount of grease for the 900 is
170gm., for the 950 model 225gm. Lubrication of the hammer is as shown on the grease charts.
SCREWS ARE TO BE REFITTED USING LOCTITE®271 OR SIMILAR
Liberally coat
Generously apply
Pack
GREASEAPPLICATIONCODE
Use grease Part No. 9170 3108 00 (85gm sachet)
Total quantity 225gm (3 sachets)
(5gm)
(5-10gm)
Place 5gm of
grease on
piston crown
Afterassembly
apply 35-40gm
(40gm)
Fillfluteslevel
with grease
(5-10gm)
Remaining
greaseafter
lubrication of all
other parts
(approx. 60gm)
(5-10gm)
Fill using
grease
gun after
assembly
(10-15gm)
SDS

22
Service and Repair Manual
Model 900/950/990
ITEM NO. PART NO. Nm lb.ft
103 9170 0020 70 2 1.75
104 9170 0193 90 3.5 2.5
113 9170 0191 70 0.75 0.5
129 9170 0191 90 2 1.75
145 9170 0070 50 22 16
151 9170 0191 10 3.5 2.5
152 9170 0197 60 1 0.75
159 9170 2874 30 2.9 2.25
162 9170 6909 00 2 1.75
168 9170 0190 80 2 1.75
227/348 9170 0190 10 16 11
229 9170 0194 20 20 15
246/365 9170 0193 20 35 25
MODELS 900KV/900SV/900MV/950K/950B/990KV
ITEM NO. PART NO. Nm lb.ft
254/382 9170 0199 70 30 21
320 9170 0190 60 7 4
321 9170 0190 60 7 4
338 9170 0190 70 4.5 3.5
341 9170 0130 10 27 20
366 9170 0198 30 18 13
TORQUE SETTINGS
Liberally coat
Generously apply
Pack
GREASEAPPLICATIONCODE
Use grease Part No. 9170 3108 00 (85gm sachet)
Total quantity 170gm (2 sachets)
(5gm)
(10gm)
Place 5gm of
grease on
piston crown
After
assembly
apply 35-
40gm
Fillfluteslevel
with grease
(5-10gm)
Remaining
greaseafter
lubrication of
all other parts
(approx.
60gm)
Fill using grease gun
afterassembly(5-10gm)
(5gm)
SDS

23
Service and Repair Manual
Model 900/950/990
ELECTRICALTESTING
ELECTRICALPERFORMANCE TESTREADINGS
Before assembly all electrical parts MUST be checked for safety, and that they conform to specification.
The recommended test voltage should be applied as follows:
1. Apply half the recommended test voltage and increase to the full recommended test voltage as rapidly
as possible.
2. The full recommended test voltage should be maintained for two to three seconds without the insulation
failing.
AArmature shaft to commutator bush 1250 volts increasing to 2500 volts
BLamination pack to armature shaft 1250 volts increasing to 2500 volts
CCommutator segments to commutator bush 750 volts increasing to 2500 volts
Connect all the field coil leads together and apply one test probe to the leads and one to the laminations.
Set the test voltage to 750 volts increasing to 1500 volts.
Clutch Slip Test
Note:- On all test readings + or - 5% of figures shown is acceptable.
Testing the
armature
(Flash
Testing)
Field coil
testing
WARNING: IF EITHER THE ARMATURE OR FIELD COIL FAILS THE PREVIOUS TESTS THE
COMPONENT MUST BE CHANGED.
AC B
ARMATURES
MODEL 100V 110V 120V 220V 240V
900 K/B/V Ω 0.514 Ω 0.66 Ω 0.66 Ω 2.84 Ω 3.04
950 K/S Ω 0.514 Ω 0.66 Ω 0.66 Ω 2.84 Ω 3.04
FIELD COILS
100V 110V 120V 220V 240V
900 K/B/V Ω 0.36 0.45 Ω 0.56 Ω 1.88 Ω 2.57
950 Ω 0.36 0.45 Ω 0.56 Ω 1.88 Ω 2.57
PERFORMANCE
Full Load Hammer Test
100V 110V 120V 220V 240V
900K/B/V 850 - 900 W
950K/S 850 - 900 W
100V 110V 120V 220V 240V
950K/S 1300 - 1400 W

24
Service and Repair Manual
Model 900/950/990
ASSEMBLY - 900/950
Assembling
the armature
(All models)
Note: In the assembly instructions numbers starting
200 are Model 900, numbers starting with 300
are Model 950, numbers starting with 400 are
Model 990, numbers starting with 500 are Model
900M in both text and illustrations.
1. Insert, into the pinion bearing cartridge (175),
bearing (141) and secure with clip (179).
2. Fit the pinion bearing cartridge assembly to the
armature shaft with the assembly against the
shoulder of the shaft.
3. Screw the pinion (145) onto the armature shaft.
Fit the pinion service tool to the pinion.
CAUTIONS::
a. During the following operation take care to
ensure the fan (138) is not damaged by the
vice jaws.
b. Failure to tighten the pinion to the correct
torque could result in damage to the hammer
gear mechanism.
4. Mount the armature assembly and pinion in a
vice, between two pieces of wood, with the pinion
nut sitting on the bottom of the vice slide.
Tighten the pinion nut (145) to 20 Nm.
Field coil switch leads
151
Armature
assembly
1. Mount the motor case (149) in a vice, using soft
metal jaws, and insert the assembled armature
into the motor case.
2. Align the holes in the pinion bearing cartridge
and secure with the two screws (151).
3. Insert the field coil (135) into the insulating liner
(136).
Note: If the field coil is fitted with inductors these
should be placed in the flat section between
the coil and the liner.
4. Insert the assembled field coil into the motor case
(149) until the top of the liner is level with the
step in the motor case.
5. Feed the two switch leads through the holes in
the liner into the switch box housing.
Assembling
the motor
(All models)
149
136
135
Fig. 23
Fig. 24
145
137
175
138
141
179

25
Service and Repair Manual
Model 900/950/990
1. Fit the two terminal housings (131).
2. Fit the two brush holders (130) into the brush
holder housing (132). Fit the brush holder
alignment service tool through the brush holders.
3. Fit the two brush holder retaining straps (114)
and four retaining screws (113).
Assembling
the brush
holder (All
models)
132
131
130
129
114
113
1. Fit the pressure ring (134), the two waved washers
(133) and the assembled brush housing. Feed field
leads through holes in brush holder housing.
Note: The brush housing is correctly located when
the housing is flush with the top of the motor
case, when light pressure is applied.
2. Connect the two field connections to the brush
terminals (130) and tighten the two terminal
screws (129).
3. Fix on the top bearing shroud (112). Lubricate and
the fit the top bearing inner ring only (126), using
service tool No. 9170 0232 40.
Assembling
the brush
housing
assembly and
rear
armature
bearing (All
models)
126
112
134
133
129
130
1. Fit the switch box liner (154) and pass the two field
coil switch leads through into the liner. Fit a
grommet (166) over each lead and press the
grommets into the liner apertures.
2. Fit switching pad (165), switch actuator plate (125)
to the two push rods (123) and pass the push rods
through the motor housing into the switch box
opening. Fit the springs (177) over the push rods
and fit the plunger abutment plate (124).
3. Fit the cord guard (169) in the cord guard housing
(167) and pass the power lead through the cord
guard ensuring there is sufficient lead available to
connect to the switch.Fit the switch cup (155), the
four terminal pads (164), the switch (159) and the
switching pad (165).
4. Fit the switch cup (155), the four terminal pads
(164), and condenser (158).Connect the switch
leads, power leads and condensor connections. Fit
the switch (159) and four terminal pads (164) into
the switch cup (164). Fit the assembled switch into
the switch box liner (154). Fit the switch box seal
(160) and switch box cover (163 and secure with
the four screws (162).
Assembling
the switch
(All models)
123
125
165
159
164
155 158
152
169
168
167
177
166
124
162
163
154
160
153
Fig. 25
Fig. 26
Fig. 27

26
Service and Repair Manual
Model 900/950/990
174
173 127
128
Assembling
the brushes
(All models)
1. Fit the two brushes (128) and the two inner brush
caps (127) (fully tighten).
2. Fit the two outer brush caps (173) and secure
with the two end cap springs (174).
Note: Run and test motor.
342
340
317
316
325
1. Fit the two terminal pads (107) to the end plate
(105).
2. Fit the washer (108) to the end plate. Apply 5gm
of grease.
3. Fit the bearing thrust washer (110) and secure
with spring ring (111). Fit the motor end plate
into the motor case (149) and locate pin in brush
holder assembly.
4. Fit the rocker assembly (101) into the handle
(118) and insert the rocker pivot pin (120). Fit
the lock button (103) and the large and small
handle plugs (102, 115).
5. Fit the plunger (121) into the handle. Fit the
handle assembly to the motor case and secure
with the four screws (104), tighten the screws in
a diagonal sequence to avoid distorting the
handle assembly.
Assembling
the motor
end plate and
rear handle
(All models)
1. Refit the clutch head bearing (340) and the drive
shaft bearing (342).
Refer to greasing instructions.
2. Refit the crank disc rear bearing (325) and insert
the bearing spacer (317). Refit the crank disc
front bearing (316).
Assembling
the gear
carrier.
(Model 950
shown)
Fig. 28
Fig. 29
Fig. 30
102
103
115
120
105
121
122
110
111
106
107
101
117
118
119
116
104
126
112
108

27
Service and Repair Manual
Model 900/950/990
Note:- Before assembly, follow greasing instructions.
1. Position the motor case (149) in a vice, using soft
metal jaw plates.
2. Fit the crank pin screw (312, 212, 412, 512),
crank pin bush (311, 211, 411, 511) and crank
pin nut (306, 206, 406, 506). Fit the thrust
bearing (314, 214, 414, 514) and the two thrust
washers (313, 213, 413, 513) onto the crank disc
(311, 211, 411, 511). Do not fit shims at this
stage.
Note: The crank pin screw and nut have left-hand
threads.
3. Fit the crank disc into the gear carrier (310, 210,
410) and carrier to motor case. Secure with a
screw (320, 220, 420, 520) and spring washer
(319, 219, 419, 519).
Assembling
the crank
disc (All
models,
Model 950
shown)
1. Press the bearing (332) into the gear (331)
2. Put clutch peg spanner in vice and place clutch
hub (333) onto pegs.
3. Fit and tighten the pinion (341) and the following
items in sequence:
a) clutch plate (330) with coating up,
b) gear (331),
c) clutch plate (330) with coating facing
the gear,
d) clutch spring (329) with concave face
to the clutch plate,
e) clutch lock washer (328)
f) clutch lock nut (327)
Assembling
the clutch
(Model 950
only)
341 327 328 329 331 332
330
333
1. The backlash between the crank disc assembly and
the motor drive is set to the limits, 0.05mm
(0.002in) and 0.08mm (0.003in). The backlash is
adjusted by adding shims to the crank disc drive
line behind the thrust race.
2. Using a feeler gauge, rotate the crank disc and
measure the gap between the back of the crank disc
and the thrust race. This should be done at the point
closest to the mesh of the crank gear and the motor
pinion.
3. Rotate crank slowly with feeler gauges in position
until it is possible to lightly nip the feelers when the
gear is rotated.Check measurement and subtract
0.05mm (0.002in) 0.08mm(0.003in)and add shim to
set backlash the running clearance.
4. Fit the three remaining gear carrier securing screws
(320, 220, 440, 520) and spring washers (319, 219,
419, 519).
Adjusting
the gear
backlash
(All models,
Model 950
shown)
149
319
419
519
318
418
518
feelergauge
311,
211
411
511
319,
219
419
519
320,
220
420
520
149
313,
213
413
513
366,
214
414
514
312,
212
412
512
310,
210
410
510
306,
206
406
506
320
420
520
Fig. 33
Fig. 31
Fig. 32

28
Service and Repair Manual
Model 900/950/990
1. Mount the clutch torque setting rig (Pt No.
9170 0236 50) in a vice and fit the clutch assembly
into the rig body with the pinion uppermost.
2. Insert a 3/16in Allen key into the pinion and rotate
counterclockwise and note the spring balance
reading when the clutch starts to slip. The reading
should be between 7-8lb (approximately 6 Nm), if
the clutch slips below this figure tighten the clutch
nut and repeat the test.
3. If during the test the clutch fails to slip remove the
clutch assembly from the rig, replace the clutch
spring (item 329) and repeat the test.
4. When the torque setting is completed secure the
clutch nut by bending up the clutch lock washer
(item 328).
Adjusting the
clutch
(Model 950
only)
336
337
338
339
345
344
343
Clutchassembly
1. Mount the motor case in a vice, between soft
metal jaw plates, with the gear carrier uppermost.
2. Fit the drive shaft thrust washer (343) and thrust
race (344) to the drive shaft (345). Insert the
drive shaft into the drive shaft bearing in the gear
carrier.
3. Insert the clutch assembly into the gear carrier
ensuring that the clutch and drive shaft pinions
are correctly engaged.
Mounting the
drive shaft
(Model 950
only)
1. Fit the following items to the clutch shaft in
sequence:
a) clutch shim (334),
b) clutch thrust race (335),
c) clutch bearing (336),
d) clutch thrust race (335),
e) clutch shaft tail bearing (337) and
f) clutch shaft bearing cap (338).
Secure the bearing cap with 2 screws (339).
2. Turn the drive shaft (345) by hand. The drive shaft
should be free to turn with a minimum of backlash
between the clutch pinion and the drive shaft. If the
backlash is excessive remove the clutch shaft
bearing cap (338) and add a shim (334). Refit the
bearing cap and four screws (339).
Note: With service tool fitted this is checked by
rotating the clutch assembly by hand.
Adjusting the
drive shaft
backlash
(Model 950
only)
Clutchassembly
Clutchtorquesettingrig
345
334
335
341
Fig. 34
Fig. 35
Fig. 36

29
Service and Repair Manual
Model 900/950/990
1. Fit the big end bearing (309, 209, 409, 509) into
the connecting rod (305, 205, 405, 505). Fit the
connecting rod over the crank pin bush (310, 210,
410, 510). Rotate the crank wheel through one
complete revolution and check that the connecting
rod does not touch the teeth of the crank disc.
Note: Connecting rod is offset
2. Fit the crank pin washer (308, 208, 408, 508) and
secure with the retainer circlip (307, 207, 407,
507).
Securing the
crank disc
(All models,
950 shown)
1. Fit the 19-tooth gear (324) or bearing keeper
(224, 424, 524) to the crank disc shaft. For the
950 models insert the gear key (326).
2. Fit the clamp plate (323, 223, 423, 523) and
secure the gear or bearing keeper using the screw
(321, 221, 421, 521) and spring washer (322,
222, 422, 522).
Fitting the
connecting
rod
(All models,
950 shown)
Fitting the
piston
(All models,
950 shown)
1. Fit the two piston seals (302, 202, 402, 502) to
the piston (303, 203, 403, 503), ensuring they are
correctly seated.
2. Insert the connecting rod (305, 205, 405, 505)
into the piston and push in the gudgeon pin (304,
204, 404, 504).
3. Lightly grease the bore of the striker (301, 201,
401, 501) and push over the piston.
301
201
401
501
302
202
402
502
303
203
403
503
305
205
405
505
304
204
404
505
321
221
421
521
326
323
223
423
523
322
222
422
522
324
224
424
524
305
205
405
505
307
207
407
507
308
208
408
508
309
209
409
509
310
210
410
510
Fig. 37
Fig. 38
Fig. 39

30
Service and Repair Manual
Model 900/950/990
1. Fit the hammer case (346, 228, 428, 528)
vertically in a vice between soft metal jaws.
2. Lightly grease the hammer case gasket (150) and
locate on the hammer case.
3. Fit the assembled motor and gear carrier into the
hammer case. For 950 models ensure the drive
shaft (345) is correctly located.
4. Secure the hammer case using the six screws
(348, 227, 427, 527) and washers (347, 226, 426,
526).
Fitting the
hammer case
(All models,
950 shown)
347
226
426
526
149
150
346
228
428
528
Fitting the
buffer
housing (All
models,
model 950
shown)
1. Press the buffer housing ring (353, 232) into the
groove in the buffer housing (354, 233).
2. Fit the buffer housing gasket (352, 231) to the
hammer casing (346, 228).
3. Fit the buffer housing (354, 208) and buffer
housing gasket (375, 234) to the hammer casing.
4. For 990 only fit spacer (432) and extra gasket
(231, 352, 433) between gasket and buffer
housing.
Assembling
the
transmitter
housing (All
models,
model 950
shown)
1. Place the transmitter housing (359) vertically in a
vice between soft metal jaws. Using service tool,
part no. 917003270, press the drive shaft bearing
(374) into the transmitter housing . Press the
driver bearing (371) into the transmitter housing
(359). (Model 950 only).
2. Insert the junk ring (373, 240), with the flat
surface down, into the driver (372) or anvil
sleeve.
3. Insert the recoil transfer ring (356, 237), rubber
ring (355, 236) into the transmitter housing.
4. Fit the two anvil rings (358, 239) on to the anvil
(357, 238) and insert the anvil into the driver
(372) or anvil sleeve. Insert the anvil and driver
assembly into the transmitter housing (369, 242).
5. Fit the assembled transmitter housing to the
hammer casing and secure with the six screws
(349, 229), spring washers (350, 230).
348
227
427
527
345
(950
ONLY)
305
205
405
505
Fig. 40
Fig. 41
Fig. 42
235
355
236
356
237
357
238
358
239
373
240
371
372
349
229
350
230
351
346
228
374
369
242
439
354
233
375
234
346
228
352
231
353
232