Doosan IR2PS, Operation And Maintenance

MAINTENANCE SECTION

6.  Remove the Pickhammer from the vise and unscrew
 

the Cylinder from the Handle.

7.  Remove the Spacer Rings (30), Valve (12), Valve Box
 

(13), Valve Pin (18) and Piston (20) from the Cylinder.

8.  Press the Nozzle (21) from the Cylinder if the Nozzle
 requires 

replacement.

9.  Using a wrench, remove the Valve Stopper (7) from
 the 

Handle.

10.  Remove the Throttle Valve Spring (6), Throttle Valve
 

Face (4) and Throttle Valve Stem (8) from the Handle.

11.  If the Inlet Bushing (10) requires replacement,
 

remove the Inlet Bushing from the Handle by using 

 a 

wrench.

ASSEMBLY

General Instructions
1.  When grasping a tool or part in a vise, always use
 

leather–covered or copper–covered vise jaws to

protect the surface of the part and help prevent

distortion.  This is particularly true of threaded

members and housings.

2.  Always clean every part and wipe every part with a
 

thin film of clean oil before installation.

3.  Apply a film of O–ring lubricant to all O–rings before
 final 

assembly.

4.  Except for press fits, parts should fit together easily. 
 

If force is required to assemble parts, the parts are 

out of alignment and must be correctly aligned 

to prevent binding and damage.

Assembly of the Pickhammer

For IR3PS and IR5PS

1.  If the Throttle Valve Stem Bushing (5) was removed,
 

press a new Bushing into the Handle (1).

2.  Position the Throttle Lever (2) in the Handle and
 

secure it by pressing the Throttle Lever Pin (3) into

the Handle and through the Throttle Lever.

3.  If the Safety Lever (1B) was removed, position the
 

Safety Lever and the Safety Lever Spring (1D) in the

Handle, with the “U”–shape of the Spring inside the

angle made by the Safety Lever.  Secure them by

pressing the Safety Lever Pin (1C) into the Handle,

and through the Safety Lever and Spring.

Safety system is to be fitted only with adapted

Safety Throttle Lever (1A).

4.  Position the Safety Throttle Lever in the Handle,
 

adjusting the “L”–shape of the Safety Lever Spring

against the edge of the Throttle Lever.  Secure it by

pressing the Throttle Lever Pin (3) into the Handle,

and through the Safety Throttle Lever.

5.  Insert the Throttle Valve Stem (6) into the Throttle
 

Valve Stem Bushing.

6.  Position the slotted end of the Throttle Valve Face (7)
 

against the Throttle Valve Stem.

7.  Install the smaller diameter end of the Throttle Valve
 

Spring (9) on the short hub of the Throttle Valve 

Pin (8).  Using the Spring to hold the Pin, install the  

long end of the Throttle Valve Pin into the Throttle  

 Valve 

Face.

8.  Install the Inlet Bushing Seal (10A) on the Inlet
 

Bushing (10) and thread the Inlet Bushing Assembly

into the Handle and tighten it to 9 ft–lb 

(12 Nm) torque.

9.  For Model IR5PS, press the new Nozzle (23) into the
 

front end of the Cylinder (22) if the Nozzle 

 required 

replacement.

10.  Install the O–ring (11) in the groove adjacent to the
 

threads on the exterior of the Cylinder.

11.  Insert the Piston (21) into the rear end of the Cylinder.
12.  For Model IR3PS, proceed as follows:
 

a.  Install the Piston Shield (17) in the threaded end

of the Cylinder with the shallow counterbored

surface toward the Piston.

b.  Stack the three Spring Washers (15) together and

position them, concave side first, against the

  Piston 

Shield.

c.  Insert the small diameter hub of the Washer Guide

(13) into the central opening of the Spring Washers.

d.  Position the Cylinder Spacer (12) against the

threaded end of the Cylinder and thread the

Handle onto the Cylinder.

For Model IR5PS, proceed as follows:
 

a.  Insert the two Valve Pins (20) into the holes in the

threaded end of the Cylinder.

b.  If the Piston Bumper (16) was separated from the

Lower Valve Seat (19) during disassembly, work

the large diameter of the Piston Bumper into the

counterbore of the Lower Valve Seat until the

Bumper is seated squarely against the Valve Seat.

c.  Slide the Lower Valve Seat, Piston Bumper first,

onto the two Pins and against the Cylinder.

d.  Position the Valve (18) in the counterbore of the

Upper Valve Seat (14) and slide the Upper Valve

Seat, Valve first, onto the Pins against the Lower

  Valve 

Seat.

e.  One or two Cylinder Spacers (12) have been

installed in these tools at the factory to locate the

Handle in the correct position at the Cylinder.

Install an identical number of Spacers of the same

thickness (1 or 2 mm thick) in the rear of the

Handle with the dished side of the Spacer facing

  the 

Valve.

f.  Thread the Handle onto the Cylinder.

13.  Using a torque wrench, tighten the Cylinder between
 

46 and 54 Nm (34 and 40 lbs.ft ) torque.

14.  Replace the handle locking screw (25). And tighten.

NOTICE

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