Ingersoll-Rand IR30BV Installation guide

This manual contains
important safety information
and must be made available
to personnel who operate and
maintain this machine
OPERATION AND MAINTENANCE
IR30BV AND IR30BS
SERIAL NO: CZ04C00001 ➔
CPN: 85040277 GB
DATE: APRIL 2004

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DISASSEMBLING THE IR30BV AND IR30BS PAVING BREAKER
GENERAL INSTRUCTIONS
• Clean the breaker outer surface.
• Do not disassemble the breaker any further than neces-
sary 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 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 breaker unless a complete set of
and O-rings is available for replacement.
DISASSEMBLY OF THE FRONTHEAD
Remove nut (25) and fronthead pinch bolt (24) from the fron-
thead (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).
Theplunger (20) andthe plunger spring(21)can be removed
from the fronthead.
Handle Disassembly (BV and BS models)
Using a hide mallet tap loose and remove the muffler (29)
from the cylinder.
Firmly grip the cylinder upright in a vice with leather or
copper cover jaws.
Loosenthe four handlescrews(26) and removenuts(27) and
washers (40 and 47).
Lift the handle assembly (5) or (42) from the cylinder assem-
bly tap with a hide mallet to loosen if necessary.
For BV models only: Press or tap out the handle pivot pin
(12)remove both handlelever(8 and 9)fromthe handle body
(5) together with the trigger (7).
Remove the handle springs (11) from their pockets.
Tap out the sleeve (13) to detach the handle levers from
each other. Remove the handle springs (11) from the handle
body (5).
If it is necessary to remove the handle stop (14),use a punch
of suitable size (15-19 mm dia.) and drift out the stop (14)
from the handle casting from the cylinder side.
It is possible at this stage to remove the trigger pin (15) if
reqiured.
Unscrew the inlet bushing (18), and remove trigger spring
(17), trigger ball (16) and throttle pin (15).
Unscrew and remove the oiler plug (39) and sealing washer
(38)anddraintheoilinthereservoirintoasuitablereceptacle
for safe disposal.
Pry out the wick plug (37) from the base of the handle ca-
sting.Inspect the wick (36) and wick holder (35) if clean and
remove if necessary.
Removethe handle grips (10)iftheyare to bereplaceditmay
prove easier to cut the grips off.
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 (5) should
not normally be necessary. If it is necessary cut off the han-
dle grips (10) and drift or press out spring pin (48). Securely
support the handle body (42) beneath a press and using a
suitablysizedpressing bar pressoutthehandlebar (43) from
the handle body (5).
Unscrew the inlet bushing (18), and remove trigger spring
(17), trigger ball (16) and trigger pin (46).
Unscrew and remove the oiler plug (39) and sealing washer
(38)anddraintheoilinthereservoirintoasuitablereceptacle
for safe disposal.
Pry out the wick plug (37) from the base of the handle ca-
sting.Inspect the wick (36) and wick holder (35) if clean and
remove if necessary.
Removethe handle grips (10)iftheyare to bereplaceditmay
prove easier to cut the grips off.
CYLINDER DISASSEMBLY
Remove the spacing washer (30) and valve plate (31). Slide
valve ring (34) from cylinder (1).
Remove sealing ring (28).
Releasethecylinderfrom the vice,invertandallowthe 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 replacement is ne-
cessary.
The cushion bushing (33) is pressed in the cylinder – do not
disassemble unless replacement is necessary.

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GENERAL INSTRUCTIONS
• Beforeassemblyofthebreaker,cleanallpartsthoroughly
and lubricate surfaces with a thin film of recommended
oil (see Lubrication).
• Applya film of O-ringlubricant toall O-ringsbefore final
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 first.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.Ifacushion is notpresent contactyour authorised
Ingersoll –Rand repair centre for advice.
CYLINDER ASSEMBLY
Gripthecylinder(1)verticallyin a vice protected with leather
or copper covered vice jaws.
Lubricate and insert the piston (4) small end first 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 fix 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.Thetrigger pin hasa reduceddiameter,which isplaced
next to the trigger ball.
Check that the handles and trigger move freely.
Assemblewick(36)inwickholder (35) and slide theassembly
intoposition in thehandle bodycasting.Retainthe assembly
in position by pressing in the wick plug (37).
Refilltheoilreservoirwithcleanair tool lubricant and replace
the seal (38) and oil fill plug (39) hand tighten only.
BS models only:
Ifthehandle bar (43) wasdisassembledfromthe 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.
Assemblewick(36)inwickholder (35) and slide theassembly
intoposition in thehandle bodycasting.Retainthe assembly
in position by pressing in the wick plug (37).
Refilltheoilreservoirwithcleanair tool lubricant and replace
the seal (38) and oil fill 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.
Notethatitis usual to orientate theair inlet andtrigger lever
180 degrees from the fronthead bolt groove in the cylinder.
Replacethe four handlescrews (26) andhandle washers(40)
and(47) using newhandlenuts (27) tightenthescrews down
evenly to a torque of 90Nm (66.4 ft.lbs).
Remove the cylinder and handle assembly from the vice.
Replace muffler (29) on the assembly by tapping the muffler
fully home using a hide mallet.
FRONTHEAD ASSEMBLY
Applyacoatingofgreasethenreplacespring (21) and plunger
(20) in position in fronthead (3).
Positionthelatch(6) in itsslot andsecure inplace bydrifting
orpressing in outerspring pin23.Positionthenpress or drift
home inner spring pin (22).
Replacefrontheadassembly onto cylinderand aligningpinch
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
thebreaker is freefromair leaks aroundtheinlet 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.
Breakeroperatingfrequency should be 1200 blows per minute
and air consumption 1.7m3/min (60 CFM) at 6 bar (90psi)
air pressure.
ASSEMBLY OF THE IR30BV AND IR30BS PAVING BREAKERS

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Ref. Part Name Quantity Cpn Ref. Part Name Quantity Cpn
1 Cylinder Assembly (28x160 Nozzle) 1 85040608 37 Wick Plug 1 85043552 1 Cylinder Assembly (32x160 Nozzle) 1 85040616 38 Seal 1 15099278 2 Nozzle 28 hex x 160 1 85040574 39 Oil Fill Plug 1 85043560 2 Nozzle 32 hex x 160 1 85040590 42 Handle Body (BS Models - Fixed Handle) 1 85043594 3 Fronthead Assembly 1 85040665 43 Handle Bar 1 85041267 3 Fronthead 1 85040673 44 Trigger 1 85041275 6 Latch 1 85040749 45 Spring Pin 1 85041283 20 Plunger 1 85040939 46 Trigger Pin 1 85043628 21 Plunger Spring 1 85040947 48 Trigger Spring Pin 1 85043610 22 Fronthead Spring Pin Inner 1 85040962 26 Handle Body Screw 4 85043636 23 Fronthead Spring Pin Outer 1 85040988 27 Handle Body Nut 4 85041010 24 Fronthead Screw 1 85041002 28 Sealing Ring 1 85041044 25 Fronthead Nut 1 85041028 29 Muffler 1 85041051 4 Piston 1 85040707 30 Spacing Washer 1 85041069 5 Handle Assembly (BV Models - Vibration Damped) 1 85043487 31 Valve Plate 1 85041093 5 Handle Body (BV Models - Vibration Damped) 1 85043503 33 Cushion Bushing 1 85041150 7 Trigger 1 85040756 34 Valve Ring 1 85041176 8 Handle Lever Left 1 85040772 40 Steel Washer 2 85043644 9 Handle Lever Right 1 85040798 47 Plastic Washer 2 85043651 10 Handle Grip 2 85040806 11 Handle Spring 2 85040822 41 Latch Kit 1 85041317 12 Handle Pivot Pin 1 85040830 6 Latch 1 85040749 13 Sleeve 1 85040848 20 Plunger 1 85040939 14 Handle Lever Stop 1 85040855 21 Plunger Spring 1 85040947 15 Trigger Pin 1 85043529 22 Fronthead Spring Pin Inner 1 85040962 16 Trigger Ball 1 85040871 23 Fronthead Spring Pin Outer 1 85040988 17 Trigger Spring 1 85040889 24 Fronthead Screw 1 85041002 18 Inlet Bushing 1 85040897 25 Fronthead Nut 1 85041028 19 Quick Coupling EU 1 85040905 Items not illustrated: 19 Quick Coupling USA 1 85040913 50 Handle Plate 1 85040244 35 Wick Body 1 85043537 51 Handle Plate Screw 4 85041325 36 Wick 1 85043545 54 Noise Sticker 112 1 85040236 37 Wick Plug 1 85043552 55 Warning Sticker 1 85040202 38 Seal 1 15099278 56 Box 1 85040178 39 Oil Fill Plug 1 85043560 57 Warranty Card 1 85040285
42 Handle Assembly (BS Models - Fixed Handle) 1 85043578 58 Box Label EU 1 85040186
10 Bar Grip 2 85040806 59 Box Label USA 1 85040194 16 Trigger Ball 1 85040871 60 Box Insert Handle 2 85041333 17 Trigger Spring 1 85040889 61 Box Insert Fronthead 2 85041341 18 Inlet Bushing 1 85040897 64 Box Space Insert 1 85041366 19 Quick Coupling EU 1 85040905 67 Operation & Maintenance Manual 1 85040277 19 Quick Coupling USA 1 85040913 69 In Line Lubricator 1 35371111 35 Wick Body 1 85043537 70 Protec Engine Oil 5l 1 85448405 36 Wick 1 85043545
PARTS LIST

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