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ASSEMBLY OF THE IR25BV AND IR25BS PAVING BREAKERS
GENERAL INSTRUCTIONS
•
Before assembly of the breaker, clean all parts
thoroughly and lubricate surfaces with a thin
fi lm of rec om mend ed 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 au tho rised
dis trib u tor.
•
The existence of a piston air cushion should be
determined. Hold the cylinder vertically and
al low the piston to drop down the bore small
di am e ter fi rst. An air cushion is present if the
pis ton "bounc es" at the bottom of the cylinder and
no metal to metal contact noise can be heard. If
a cushion is not present contact your au tho rised
Ingersoll-Rand re pair 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 cyl-
in der (1) and replace valve cover (31).
Position the valve spacer (30) on top of the valve
cov er (31).
Replace the sealing ring (28).
HANDLE ASSEMBLY
BV models only:
If the handle stop (14) was removed during dis as sem-
bly it should be replaced with a new part as the
retaining feature is severed on removal. Locate the
stop in the hole in the handle and tap sharply into
place using a soft drift and hammer.
If the hand grip rubbers (10) have been removed
these should now be replaced. Lubricate the inside
of the rubber with soapy water and slide the new
rubber into position, retain each rubber with wash er
(39) and screw (40) (if fi tted).
Assemble left and right hand, hand grips (8 and 9),
trigger (7) together with sleeve (13), lubricate around
the pivot area and position the sub assembly along
the slot in handle body (5).
Note it is usual to position the trigger lever
on the same side as the air inlet of the handle
body.
Locate the handle springs (11) between hand grips
and handle body and fi x the assembly in place by
drifting or pressing in handle pivot pin (12).
Lubricate the trigger pin (15) , trigger ball (16) and
replace in the air inlet connection of the handle
body.
Note the trigger pin has a reduced diameter
which is placed next to the trigger ball.
Locate the trigger spring (17) on top of the trigger
ball. Apply thread retainer (loctite 243, or similar)
on the thread of the inlet bushing (18) and tighten
to 200 Nm (147 lb.ft) torque.
Check that the handles and trigger move freely.
BS models only:
If the handle bar has been disassembled from the
handle body.
Securely support the handle body (42) beneath
a press and position the handle bar (43) in the mat ing
body hole.
52
Note: Ensure that the handle bar has the
cor rect orientation and alignment to accept
the trigger pin (45) when pressed home.
Press home the handle bar to depth until the lock
pin-hole is aligned.
Press or drift in the lock spring pin.
Lubricate and replace the trigger pin (46). Note the
trigger pin has a reduced diameter which is placed
next to the trigger ball.
Check that the trigger pin can move freely.
Position the trigger lever (44) and secure in place
with spring pin (45)
Lubricate the trigger pin (46), trigger ball (16) and re-
place in the air inlet connection of the handle body.
Note the trigger pin has a reduced diameter
which is placed next to the trigger ball.
Locate the trigger spring (17) on top of the trigger
ball. Apply thread retainer (loctite 243, or similar)
on the thread of the inlet bushing (18) and tighten
to 200 Nm (147 lb.ft) torque.
Check that the trigger moves freely.
Lubricate the inside of the handle grip rubber (47)
with soapy water and slide the new rubber into po-
si tion.
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 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 muffl er ring (32) in muffl er (29)and re place
the assembly by tapping the muffl er fully home us ing
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). Po si 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 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 break er
does not au to mat i cal ly 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 hes i-
ta tion.
Breaker operating frequency should be 1320 blows
per minute and air consumption 1.3m
at 6 bar (90psi) air pressure.
3
/min (46CFM)
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