52
GENERAL INSTRUCTIONS
• Before assembly of the breaker, clean all parts thoroughly
and lubricate surfaces with a thin fi lm of recommended
oil (see Lubrication).
• Apply a fi lm of O-ring lubricant to all O-rings before fi nal
assembly.
• It is recommended that the assembling of the nozzle (2)
and the cushion bushing (33) should be carried out by
the manufacturer or authorised distributor.
• The existence of a piston air cushion should be deter-
mined. Hold the cylinder vertically and allow the piston
to drop down the bore small diameter fi rst. An air cush-
ion is present if the piston “bounces” at the bottom of
the cylinder and no metal to metal contact noise can be
heard. If a cushion is not present contact your authorised
Ingersoll –Rand repair centre for advice.
CYLINDER ASSEMBLY
Grip the cylinder (1) vertically in a vice protected with leather
or copper covered vice jaws.
Lubricate and insert the piston (4) small end fi rst into the
bore. - Check for cushion.
Lubricate and slide the valve ring (34) onto the cylinder (1)
and replace valve cover (31).
Position the valve spacer (30) on top of the valve cover (31).
Replace the sealing ring (28).
HANDLE ASSEMBLY
BV models only:
If the handle stop (14) was removed during disassembly it
should be replaced with a new part as the retaining feature
is destroyed upon removal. Locate the stop in the hole in the
handle casting and tap the stop sharply into place using a
soft drift and hammer.
If the hand grip rubbers (10) were removed these may now
be replaced. Lubricate the inside of the rubber with soapy
water and slide the new rubbers into position.
Assemble left and right hand grips (8 and 9), trigger (7)
together with sleeve (13) , lubricate around the pivot area
with oil, and position the sub-assembly in the slot in the
handle body (5).
Locate the handle springs (11) in place beneath the hand
grip assembly, compress the springs slightly and fi x the
whole assembly in place by drifting or pressing the handle
pivot pin (12).
Lubricate and slide trigger pin (15) into position in the han-
dle casting, replace trigger ball (16) trigger spring (17) and
replace air inlet bushing (18) apply thread retainer (Loctite
243, or similar) to the threads.
Tighten the inlet bushing to a torque of 200Nm (147ft.lbs)
torque.
Note. The trigger pin has a reduced diameter, which is placed
next to the trigger ball.
Check that the handles and trigger move freely.
Assemble wick (36) in wick holder (35) and slide the assembly
into position in the handle body casting. Retain the assembly
in position by pressing in the wick plug (37).
Refi ll the oil reservoir with clean air tool lubricant and replace
the seal (38) and oil fi ll plug (39) hand tighten only.
BS models only:
If the handle bar (43) was disassembled from the handle body
(42) it should now be replaced. Securely support the handle
body (42) beneath a press and position the handle bar (43)
in the mating hole.
Note: Ensure that the handle bar has the correct ori-
entation and is aligned to accept the trigger pin (45)
when pressed home.
Press the handle bar home to depth until the lock pin hole
is aligned.
Press or drift in the lock spring pin (48).
Lubricate and slide the trigger pin (46) into position in the
handle casting, replace trigger ball (16), trigger spring (17)
and replace inlet bushing (18) apply thread retainer (Loctite
243, or similar) to the threads.
Tighten the inlet bushing to a torque of 200Nm (147ft.lbs)
torque.
Note. The trigger pin has a reduced diameter, which
is placed next to the trigger ball.
Position trigger lever (44) and secure in place with spring
pin (45) Check the trigger moves freely.
Assemble wick (36) in wick holder (35) and slide the assembly
into position in the handle body casting. Retain the assembly
in position by pressing in the wick plug (37).
Refi ll the oil reservoir with clean air tool lubricant and replace
the seal (38) and oil fi ll plug (39) hand tighten only.
If the hand grip rubbers (10) were removed these may now
be replaced. Lubricate the inside of the rubber with soapy
water and slide the new rubbers into position.
MAIN ASSEMBLY
Lightly grip the cylinder assembly vertically in a vice and
position the handle assembly in place.
Note that it is usual to orientate the air inlet and trigger lever
180 degrees from the fronthead bolt groove in the cylinder.
Replace the four handle screws (26) and handle washers (40)
and (47) using new handle nuts (27) tighten the screws down
evenly to a torque of 90Nm (66.4 ft.lbs).
Remove the cylinder and handle assembly from the vice.
Replace muffl er (29) on the assembly by tapping the muffl er
fully home using a hide mallet.
FRONTHEAD ASSEMBLY
Apply a coating of grease then replace spring (21) and plunger
(20) in position in fronthead (3).
Position the latch (6) in its slot and secure in place by drifting
or pressing in outer spring pin 23. Position then press or drift
home inner spring pin (22).
Replace fronthead assembly onto cylinder and aligning pinch
bolt hole with the cylinder groove.
Replace pinch bolt (24) and nut (25) and tighten a torque of
200 Nm (147 lb.ft) torque.
ASSEMBLY CHECKS
Following service the breaker should be checked for correct
operation prior to being released back to the job site.
Fit the correct size accessory into the breaker and connect to
an airline. Using air at low pressure 2 bar (30psi), check that
the breaker is free from air leaks around the inlet connection
and that the breaker does not automatically start to operate
without the trigger being depressed.
Increase the air pressure to 6 bar (90psi) and run the tool in
short bursts to check the tool operates correctly and stops
and starts cleanly without hesitation.
Breaker operating frequency should be 1200 blows per minute
and air consumption 1.7m
3
/min (60 CFM) at 6 bar (90psi)
air pressure.
ASSEMBLY OF THE IR30BV AND IR30BS PAVING BREAKERS
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