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bushing arbor and insert it into the Handle through the threaded
opening at the base of the grip.
Press the Bushing until its trailing face is 1-21/32” (42.06 mm)
below the face of the throttle valve cap oss on the Handle.
Using a plunger bushing reamer guide and a throttle valve
plunger bushing reamer, ream the Throttle Valve Plunger Bushing
to size.
Install Throttle Valve Plunger (6), Throttle Valve Ball (5), Throttle
Valve Spring (8) and Throttle Valve Cap (9).
Align Throttle Lever (2) in Handle and drive in Throttle Lever Pin
(3).
Reposition the tool in a vise with leather-covered or copper-
covered jaws by clamping the Handle across the Throttle Lever Pin
with the Barrel up.
Slide Locking Ring (20) over splines on Barrel, aligning
castellations on Locking Ring with castellations in Handle. Tap
Locking Ring lightly in several places to secure in position.
Spread apart and install the Exhaust Deflector (21).
Install new Nozzle (24) after Tool has been assembled. Using a soft
hammer, start new Nozzle, externally beveled end first, squarely
into Barrel bore.
NOTICE
Installation of a Hexagon Nozzle requires a 50 ton press.
For Hexagon Nozzles, position a flat of the Nozzle at the top
so that the chisel blade will be installed in the correct
operating position. Support the Handle directly beneath the
Barrel and using a 50 ton press, press in the new Nozzle until
it seats.
11. Install Retainer (33) on front of Barrel and secure with
Lock Spring (33A) or Flat Spring and Pin (33B).
Installation of Oversize Piston
NOTICE
Do not install an oversize Piston without first lapping the
Barrel.
Greater wear occurs near the center of the barrel bore than at either
end. To obtain full benefit from an oversize Piston (22), it is necessary
to lap the Barrel (23) until the bore is of uniform size for its entire
length. Select and install the proper size Piston after truing up the
Barrel bore. Pistons are furnished .004”, .008” or .012” oversize.
3.
4.
5.
6.
7.
8.
9.
10.
Installation of Oversize Nozzle
Steel hexagon or round nozzles are furnished with outside diameters
of .0005” oversize.
The Nozzle must be a tight press fit in the front of the Barrel (23).
After the Nozzle has been replaced a few times, the Barrel may
become enlarged to the extent that the Nozzle is no longer tight.
If this condition is noted, an oversize Nozzle should be used. The
oversize Nozzle is plainly etched with the amount of oversize; a
standard Nozzle is unmarked. Examine a Nozzle that can be pressed
easily from the Barrel. If it is unmarked, use the .0005” oversize when
reassembling the Chipper. See MAINTENANCE TOOLS for Nozzle
removal tool.
Installation of Oversize Inlet Bushing
This part is available .012” oversize. It should be used only in cases
where the threads in the Handle have become worn to the extent
that air leakage is noted. A special tap must be used to oversize the
threads in the Handle before the oversize Bushing can be installed.
Replacement of Throttle Valve Guide (8) in Handle. (For “A” Series and
“W” Series Chipping Hammers with first two letters of serial number
SA through SP).
Tap the worn Throttle Valve Guide (8) to a 9/16”-12 thread.
Thread a 9/16”-12 thread Cap Screw into the Guide, grasp the
head of the Cap Screw in a vise and pull the Guide from the
Handle (1).
Using the No. HH-607 Throttle Valve Guide Inserting Tool, press
the new Throttle Valve Guide into the Handle until the shoulder
on the Inserting Tool contacts the face of the throttle valve cap
boss on the Handle. If a piloted arbor is used instead of the
Inserting Tool, press the Throttle Valve Guide into the Handle until
its trailing face is 37/64” (14.68 mm) below the face of the throttle
valve cap boss.
Installation of Throttle Valve Plunger Bushing (7) in Handle
(For “A” Series and “W” Series Chipping Hammers with first two
letters of serial number SA through SP)
Slide the new Throttle Valve Plunger Bushing (7) over a plunger
bushing arbor and insert it into the Handle through the threaded
opening at the base of the grip.
Press in the Bushing until its trailing face is 1-21/32” (42.06 mm)
below the face of the throttle valve cap boss on the Handle.
Using a plunger bushing reamer guide and a throttle valve
plunger bushing Reamer, ream the Throttle Valve Plunger Bushing
to size.
1.
2.
3.
1.
2.
3.
Trouble Shooting Guide
Trouble
Probable Cause
Solution
Sluggish operation
Dirt or oil gum accumulation on internal
parts
Pour about 3 cc of a clean, suitable, cleaning solution into the
air inlet and operate for 30 seconds. After flushing, pour about
3 cc of oil into the air inlet and operate the tool for 5 seconds to
coat the internal parts with oil.
Loss of power
Worn Valve
Replace the Valve.
Loss of efficiency
Worn Piston and/or accessory
Replace Piston and or accessory.
Related Documentation
For additional information refer to:
Air Percussive Chipping Hammer Product Safety Information Manual 04581450.
Air Percussive Chipping Hammer Product Information Manual 16574162.
Air Percussive Chipping Hammer Parts Information Manual 16574329.
Manuals can be downloaded from ingersollrandproducts.com
