10
GENERAL INSTRUCTIONS
•
Clean the breaker outer surface.
•
Do not disassemble the breaker any further than
necessary to replace or repair damaged or worn
parts.
•
Whenever grasping a breaker or a part in a vice,
always use leather or copper-covered vice jaws
to protect the surface of the part and help pre-
vent distortion. Take extra care with threaded
parts and housings.
•
Do not remove any part that is a press fit in or
on a subassembly unless the removal of the part
is necessary for repairs or replacement.
•
Do not disassemble the breaker unless a com-
plete set of and O-rings is available for replace-
ment.
DISASSEMBLY OF THE FRONTHEAD
Remove nut (25) and fronthead pinch bolt (24) from
the fronthead (3). Lightly tap the fronthead (using a
hide mallet if necessary) from the cylinder (1).
Press or drift out the two fronthead spring pins (22,
23) and remove the latch (6).
The plunger (20) and the plunger spring (21) can be
removed from the fronthead.
Handle Disassembly (BV and BS models)
Using a hide mallet tap loose and remove the muf-
fler (29) and the muffler ring (32) from the cylinder.
Firmly grip the cylinder upright in a vice with leather
or copper covered jaws.
Loosen the four-handle nuts (27), unscrew and re-
move the four-handle screw’s (26).
Lift the handle assembly (5) or (42) from the cylin-
der (1) (tap with a hide mallet if necessary).
For BV models only: Press or tap out the handle
pivot pin (12), remove both handle levers (8 and 9)
from the handle body (5) together with the trigger
(7). Tap out the sleeve (13) to detach the handle le-
vers from each other. Remove the handle springs (11)
from the handle body (5). If it is necessary to remove
the handle lever stop (14), use a punch of a suitable
size (
∅
15 – 19 mm) and drift the stop out from the
cylinder side.
It is possible to remove the trigger pin (15) at this
stage if required.
Unscrew the inlet bushing (18), and remove trigger
spring (17) the trigger ball (16) and throttle pin (15).
Remove the handle screws (40) and washers (39) and
remove the handle grips (10). It may prove easier to
cut off the old handle grips if they are to be replaced.
For BS models only: Drift or press out the spring
pin (45) and remove the trigger lever (44)
The trigger pin (46) may be removed at this stage if
required.
Removal of the handle bar (43) from the casting
should not normally be necessary. If this is required
first cut off the rubber hand-grips (10) and drift or
press out the lock spring pin (45). Securely support
the handle body (42) beneath a press and using a
suitably sized pressing bar press the handle bar out
of the handle body.
Unscrew the inlet bushing (18), and remove trigger
spring (17) the trigger ball (16) and trigger pin (46).
Remove the handle screws (40) and washers (39) and
remove the handle grips (47). It may prove easier to
cut off the old handle grips if they are to be replaced.
Cylinder Disassembly
Remove the spacing washer (30) from the valve cov-
er. Lift off valve plate (31), and slide valve (35), out
from the valve body (36), valve ring (37).
Remove the two valve pins (38) from the cylinder.
Release the cylinder from the vice, invert and allow
the piston (4) to slide out and be caught.
The nozzle (2) is pressed in the cylinder and retained
with Loctite 601 – do not disassemble unless replace-
ment is necessary.
ASSEMBLY OF THE IR15BV AND IR15BS PAVING BREAKERS
Lightly grip the cylinder assembly vertically in a vice
and position the handle assembly in place.
Note that it is usual to orientate the trigger
lever and air inlet 180 degrees from the front-
head bolt groove in the cylinder.
Replace the four handle screws (26) use new handle
nuts (27) and tighten down evenly to a torque of 90
Nm (66.4 lb.ft) torque.
Remove the cylinder and handle assembly from the
vice.
Assemble muffler ring (32) in muffler (29) and re-
place the assembly by tapping the muffler fully home
using a hide mallet.
FRONT HEAD 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). Posi-
tion then press or drift home inner spring pin (22).
Replace fronthead assembly onto cylinder and align-
ing pinch bolt hole with the cylinder groove.
Replace pinch bolt (24) and nut (25) and tighten a
torque of 90 Nm (66.4 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 break-
er 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 hesi-
tation.
Breaker operating frequency should be 1200 blows
per minute and air consumption 0.7m
3
/min (26CFM)
at 6 bar (90psi) air pressure.
DISASSEMBLING THE IR15BV AND IR15BS PAVING BREAKER
