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Service and Repair Manual

Model 810V

Assembling
the spindle
assmbly

Refit O-ring (263) and fit spindle extension (262)
onto spindle (265), secure using four drive pins
(264).

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)

Fit the following items into spindle assembly (265):
- O-ring (266)
- ram (271)
- thrust washer (270)
- damping washer (269)
- cushion washer (268)

Fit spindle assembly into intermediate housing (254)
and fit the following items:
- stiker (267)
- O-ring (266)

Fit the barrel assembly into the crankcase (275)
and secure using two screws (272).

Fit O-ring (266) onto striker (271) and assemble
into barrel (273).

Assembling
the barrel
assembly

Fit bearing (205) in cap (206), fit circlip (205).

Fit seal (207), cover (201) and secure using four
screws (204) and screw (203).

Fit cap (202).

Refitting the
crankcase
top cover

273

266

275

271

272

261

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

Содержание 810

Страница 1: ......

Страница 2: ... 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 ...

Страница 3: ... 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 a...

Страница 4: ...4 130 129 126 126 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 13...

Страница 5: ... 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 ...

Страница 6: ...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 ...

Страница 7: ...g 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 sp...

Страница 8: ... 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 ...

Страница 9: ...LL 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 EY...

Страница 10: ...n 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 ...

Страница 11: ...ator 3000 Volts min ELECTRICAL TESTING ELECTRICAL PERFORMANCE TEST READINGS 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 96Ω 3 705Ω 3 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 Armatu...

Страница 12: ...utch 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...

Страница 13: ...70 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 ...

Страница 14: ...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...

Страница 15: ...n 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...

Страница 16: ...d 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 ...

Страница 17: ...ver 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...

Страница 18: ...ly 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 stress...

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