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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 DCT3PS and DCT5PS
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.
N OTIC E
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.
All manuals and user guides at all-guides.com
MAINTENANCE SECTION
9. For Model DCT5PS, press the new Nozzle (23) into
10. Install the O–ring (11) in the groove adjacent to the
11. Insert the Piston (21) into the rear end of the Cylinder.
12. For Model DCT3PS, proceed as follows:
For Model DCT5PS, proceed as follows:
13. Using a torque wrench, tighten the Cylinder between 46
14. Replace the handle locking screw (25). And tighten.
70
the front end of the Cylinder (22) if the Nozzle required
replacement.
threads on the exterior of the Cylinder.
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.
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.
and 54 Nm (34 and 40 lbs.ft ) torque.
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