Ingersoll Rand IR23JV Exploitation Et Entretien page 51

DISASSEMBLING THE IR23JV AND IR23JS JACKHAMMER
GENERAL INSTRUCTIONS
• Clean the outer surface of the jackhammer.
• Do not disassemble the jackhammer any further than is
necessary to replace or repair damaged or worn parts.
• Whenever grasping the jackhammer in a vice, always
use leather or copper covered vice jaws to protect the
surface of the part and help to prevent distortion. Take
extra care with threaded parts and housings.
• Do not remove any part that is a press fit in or on a sub-
assembly unless the removal of the part is necessary for
repairs or replacement.
• Do not disassemble the jackhammer unless a complete
set of seals and o-rings is available for replacement.
DISASSEMBLY OF THE FRONTHEAD
Support the jackhammer on a suitable bench and remove
side rod nuts (2).
NOTE: do not grip the jackhammer by its muffler in a vice
as the muffler is aluminium and may be crushed.
Carefully slide off fronthead (3) complete with spring re-
tainer (1).
CAUTION: Take care when removing the fronthead as other
parts may be released from their location and could fall.
The fronthead requires no maintenance apart from lubrica-
tion provided by use of a suitable airline lubricator during
operation of the jackhammer. Check the retainer spring (1)
for signs of obvious wear and replace if necessary.
Should replacement of retainer spring (1) be required, grip
the jackhammer firmly in a vice equipped with leather or
copper covered vice jaws and use a suitable flat metal bar as
a lever to disengage the spring tang from its location in the
side of the fronthead casting (3).
CAUTION: There is considerable energy stored in the spring
take care to wear eye protection and gloves. Guard against
sudden energy release during spring removal.
DISASSEMBLY OF DRILLING COMPONENTS
Leave the side rod bolts (42) in position through the assembly
at this stage. Remove chuck (4) slide from location, note that
the chuck may lie contained within the fronthead (3).
Inspect the chuck nut (5) for signs of wear and replace if nec-
essary. If worn the nut can be removed using tool no 1 included
in maintenance kit cpn 15909880, alternatively an old piston
with a bar welded across may be used as a wrench.
NOTE: the chuck nut has a left hand thread.
Remove impact sleeve (6) which may be retained on the end
of the piston (10).
Remove piston (10) from cylinder (8). Remove O-ring (7) and
slide off muffler (9) together with cylinder (8), which is a
press fit into muffler (9).
NOTE: Take care not to loose pin (49), which locates muffler
(9) and valve body (13).
DISASSEMBLY OF MOTOR COMPONENTS
Withdraw side rod bolts (42).
Remove handle body assembly (61) or (62) as an assembly
from cylinder head.
Carefully split cylinder head (26) from ratchet plate (17) and
set cylinder head aside.
Withdraw rifle bar (19) with blow tube (18) and ratchet plate
(17) from valve cap (16) and set aside. Take care to prevent
loss of pawls (20) plungers (21) and plunger springs (22)
which are spring loaded.
NOTE: Blow tube (18) is press fit in rifle bar (19).
Split apart valve cap (16), valve housing (15) and valve body
(13) and remove slide valve (14).
NOTE: Remember orientation of valve housing (15) to aid
re-assembly.
Inspect rifle nut (11) for wear. If worn the nut can be removed
using tool no. 2 included in maintenance kit cpn 15909880,
alternatively an old rifle bar with a suitable bar welded across
may be used as a wrench.
Unscrew the rifle nut (11) from the piston (10).
NOTE: The nut (11) has a left hand thread.
DISASSEMBLY OF RATCHET MECHANISM
Carefully slide rifle bar (19) complete with blow tube (18)
from ratchet plate (17). Take care to retain the pawls (20),
plungers (21) and springs (22).
DISASSEMBLY OF CYLINDER HEAD
Grip the cylinder head (26) in a vice and using a suitably
sized drift remove the plastic closing pins (30).
Remove the cylinder head (26) from the vice and invert the
part upside down above a wiper or other suitable receptacle
to catch the small ball bearings (29) that retain the throttle
valve lever (23) in place.
Encourage the 14 ball bearings on each side to drop out of
their groove by operation of the throttle valve lever (23) or air
inlet tube (28) depending on which is to be removed.
Once all balls have been removed, the throttle lever or the air
inlet tube may be slid out of the cylinder head (26).
Take care to retain the throttle detent plunger (25) and its
spring (24). Remove the air inlet sealing ring (27).
DISASSEMBLY OF HANDLE ASSEMBLY
JV MODELS
Grip the handle body (32) in leather or copper protected vice
jaws. Press or drift out handle pivot pin (33) using a suitably
sized drift.
Remove both handle levers (36) from the slot in the handle
body.
Tap out sleeve (41) to split the handle levers apart from each
other Remove the handle springs (35).
If it is necessary to remove the handle lever stop (34) use a
punch of suitable size (15 – 19 mm) and drift out the stop
from the cylinder side of the handle body (32).
NOTE: Removal of handle stop (34) will destroy the retain-
ing lip of the stop and a new one should be fitted on re-as-
sembly.
Remove the handle grips (38). It may prove easier to cut off
the old grips with a sharp knife.
JS MODELS
Grip the handle body (43) in leather or copper protected
vice jaws. Remove nut (47) and washer (48) from handle
bar end. Press or drift out handle bar (46) using a suitably
sized drift.
Spacer tubes (44) will be retained inside the handle grips
(45). If it is necessary to replace handgrip (45) it may prove
easier to cut off the old grips with a sharp knife.
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