This manual containsimportant safety informationand must be made available to personnel who operate andmaintain this machine

OPERATION AND MAINTENANCE

IR10PV AND IR12PV

SERIAL NO: CZ02G00001 ➔

CPN: 85042927 GBDATE: 07/2002

2

PORTABLE POWER PRODUCT WARRANTY

Ingersoll-Rand, through its distributor, war rants that each item of equipment man u fac tured by it and de liv ered here un-der to the ini tial user will be free of de fects in material and workmanship for a period of three (3) months from ini tial op er a tion or six (6) months from the date of ship ment to the initial user, which ev er oc curs fi rst.

With respect to the following types of equip ment, the war- ran ty period enumerated below will ap ply in lieu of the fore-go ing warranty pe ri od.

A. Aftercoolers – The earlier of nine (9) months from date of shipment to or six (6) months from ini tial op er a tion by initial user.

B. Portable Compressors, Portable Gen er a tor Sets – 9 Kva through to 550 Kva, Por ta ble Light Tow- ers and Air Dryers – The ear li er of twelve (12) months from ship ment to or the ac cu mu la tion of 2,000 hours of op er a tion by the ini tial user.

2.5 Kva Through to 8 Kva – The earlier of twelve (12) months from shipment to or the ac cu mu la tion of 2,000 hours of operation by the initial user.Ingersoll-Rand will provide a new part or re paired part, at it’s sole discretion, in place of any part which is found to be defective in ma te ri al or work man ship during the period de scribed above. La bour cost to re place the part is the re spon si bil i ty of the ini tial user.

C. Portable Compressor Air Ends – The ear li er of twen ty-four (24) months from ship ment to or the ac cu mu la tion of 4,000 hours of op er a tion by the ini tial user. For Air Ends, the war ran ty against de fects will in clude re place ment of the complete Air End, pro vid ed the orig i nal Air End is returned as sem bled and all orig i nal seals are in tact.

D. Portable Compressor Airend Lim it ed Ex tend ed Warranty – The earlier of sixty (60) months from ship- ment to or the ac cu mu la tion of 10,000 hours of op er a tion by the ini tial user. This ex tend ed war ran ty is lim it ed to defects in de sign or de fec tive ma te ri al or work man ship in rotors, housings, bear ings and gears and pro vid ed all the following con di tions are met:

1. The original air end is returned as sem bled and all orig i nal seals are intact.

2. Continued use of genuine Ingersoll-Rand parts, fl u ids, oil and fi lters.

3. intervals by authorised and properly trained ser vice en gi neers.

E. Generator Alternator – 9 Kva through to 550 Kva, the earlier of twenty-four (24) months from ship ment to or the ac cu mu la tion of 4,000 hours of op er a tion by the initial user.

2.5 Kva Through to 8Kva – The earlier of twelve (12) months from shipment to or the ac cu mu la tion of 2,000 hours of operation by the ini tial user.

F. Portable Light Tower Alternator – The ear li er of twelve (12) months from ship ment to or the ac cu mu-la tion of 2,000 hours of operation by the initial user. Light Source mod el only, the ear li er of twen ty-four (24) months from ship ment to or the ac cu mu la tion of 4,000 hours of op er a tion by the ini tial user.

G. Ingersoll-Rand Engines – The earlier of twen ty-four (24) months from shipment to or the ac cu mu la tion of 4,000 hours of op er a tion by the ini tial user.

H. Ingersoll-Rand Platinum Drive Train Lim it ed Ex-tend ed Warranty – Plat i num drive train refers ot the Ingersoll-Rand En gine and Airend com bi na tion. The ear-

li er of sixty (60) months from ship ment to, or the ac cu mu-la tion of 10,000 hours of op er a tion by the ini tial user. The starter, alternator, fuel in jec tion sys tem and all elec tri cal com po nents are ex clud ed from this ex tend ed war ran ty. The airend seal and drive cou pling are in clud ed in the warranty but airend drive belts are ex clud ed. This lim-ited extended warranty is au to mat i cal ly avail able when meet ing the fol low ing con di tions:

1. The original airend is returned as sem bled and un-opened.

2. Continued use of genuine Ingersoll-Rand parts, fl u ids, oil and fi lters.

3. Maintenance is performed at prescribed in ter vals by au tho rised and properly trained ser vice en gi neers.

I. 1. Construction Tools, (Portable Pow er range only) – Twelve months from ship ment to ini tial user. In ger soll-Rand will provide a new part or repaired part, at it’s sole dis cre tion, in place of any part which is found to be de fec tive in material or workmanship dur ing the period de scribed above. Labour cost to re place the part is the re spon si bil i ty of the ini tial user.

2. Construction Tools Limited Ex tend ed War- ran ty, (Portable Power range only) – Thir ty-six (36) months from shipment to ini tial user. This ex tend ed warranty is au to mat i cal ly avail able only when the tool is reg is tered with In ger soll-Rand by completing and sub mit ting the War ran ty Reg is tra tion form. In ger soll-Rand will provide a new part or re paired part, at it’s sole dis cre tion, in place of any part which is found to be de fec tive in ma te ri al or work man ship dur ing the pe ri od de scribed above. La bour cost to re place the apart is the re spon si bil i ty of the ini tial user.

J. Spare Parts – Six (6) months from date of ship ment to the initial user. Ingersoll-Rand will provide a new part or re paired part, at its sole discretion, in place of any part that is found to be defective in material and work man ship dur ing the period described above. Such parts will be re paired or replaced without charge to the ini tial user during normal working hours at the place of business of an Ingersoll-Rand dis trib u tor au tho rised to sell the type of equipment in volved or oth er es tab lish ment au tho rised by Ingersoll-Rand. User must present proof of purchase at the time of ex er cis ing war ran ty. The above war ran ties do not ap ply to failures oc cur ring as a result of abuse; mis use, negligent repairs, cor ro sion, erosion and nor mal wear and tear, alterations or mod i fi ca tions made to the product without express writ ten con sent of In ger soll-Rand; or failure to follow the rec om mend ed op er at ing practices and maintenance procedures as pro vid ed in the prod uct’s operating and maintenance publications.

Accessories or equipment furnished by Ingersoll-Rand, but manufactured by others, including, but not limited to, en gines, tires, batteries, engine electrical equip ment, hy drau lic trans mis sions, carriers, shall carry only the man u fac tur ers war ran ty, which In ger soll-Rand can law- ful ly assign to the initial user.

THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTH ER WARRANTIES EXPRESSED OR IM PLIED, (EX CEPT THAT OT TITLE0, AND THERE ARE NO WARRANTIES OF MER-CHANT ABIL I TY OR OF FITNESS FOR A PARTICULAR PURPOSE.

3

Machine models represented in this manual may be used in various locations world-wide. Machines sold and shipped into European common market countries requires that the machine display the EC Mark and con form to various di rec tives. In such cases, the design specifi cation of this machine has been certifi ed as complying with EC directives. Any modifi ca-tion to any part is absolutely prohibited and would result in the CE cer ti fi ca tion and marking being rendered invalid. A declaration of that conformity follows:

IR10PV and IR12PV

1-7-2002

07/2002

IR10PV

IR12PV

10 kg

12 kg

98

100

1-7-2002

GB

15

Look for these signs on machines shipped to mar kets in North America, which point out potential haz ards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow in struc tions. If you do not understand, inform your supervisor.

Red BackgroundIndicates the presence of a hazard which WILL cause se ri ous injury, death or property damage, if ignored.

Yellow BackgroundIndicates the pres ence of a hazard which WILL or can cause in ju ry or prop er ty damage, if ignored.

Orange BackgroundIndicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored.

Blue BackgroundIndicates im por tant set-up, op er at ing or main te nance in for-ma tion.

IR10PV and IR12PV Pick Hammers are designed for the disintegration of low to medium strength materials (e. g. concrete, masonry bituminous as phalt etc). The tool is intended for vertical or inclined down ward break ing.Ingersoll – Rand is not responsible for customer mod i fi ca tions of tools for applications on which Ingersoll – Rand was not consulted.

IMPORTANT SAFETY INFORMATION EN CLOSED.READ THIS MANUAL BEFORE OPERATING TOOL.

IT IS THE RESPONSIBILITY OF THE EM PLOY ER TO PLACE THE INFORMATIONIN THIS MANUAL INTO THE HANDS OF THE OPERATOR.

FAILURE TO OBSERVE THE FOLLOWING WARN INGS COULD RESULT IN INJURY.

PLACING TOOL IN SERVICE

• Always operate, inspect and maintain this tool in ac cor-dance with all regulations (local, state, fed er al and coun try), that may apply to hand held/hand operated pneu mat ic tools.

• For safety, top performance, and maximum du ra bil i ty of parts, operate this tool at 103 psig (7.0 bar/700 kPa) maximum air pressure at the inlet with 3/4” (19 mm) inside diameter air supply hose.

• Always turn off the air supply and dis con nect the air supply hose before installing, removing or ad just ing any accessory on this tool, or before per form ing any main te-nance on this tool.

• Do not use damaged, frayed or deteriorated air hoses and fi ttings.

• Be sure all hoses and fi ttings are the correct size and are tightly secured. See Dwg. PP1 for a typical piping ar range ment.

• Always use clean, dry lubricated air at 103 psig (7.0 bar/700 kPa) maximum air pressure. Dust, corrosive fumes and/or excessive moisture can ruin the motor of an air tool.

• Do not lubricate tools with fl ammable or vol a tile liquids such as kerosene, diesel or jet fuel.

• Do not remove any labels. Replace any dam aged label.

USING THE TOOL

• Always wear eye protection when operating or per form ing maintenance on this tool.

• Always wear hearing protection when op er at ing this tool.

• Keep hands, loose clothing and long hair away from ro-tat ing end of tool.

• Anticipate and be alert for sudden changes in motion during start up and operation of any pow er tool.

• Keep body stance balanced and fi rm. Do not over reach when operating this tool.

• Tool accessories may continue to impact briefl y after throt tle is released.

• Air powered tools can vibrate in use. Vi bra tion, re pet i tive motions or uncomfortable positions may be harmful to your hands and arms. Stop using any tool if dis com fort, tingling feeling or pain oc curs. Seek medical advice be-fore re sum ing use.

• Use accessories recommended by Ingersoll-Rand.• This tool is not designed for working in ex plo sive at mo-

spheres.• This tool is not insulated against electric shock.

The use of other than genuine Ingersoll-Rand re place ment parts may result in safety hazards, de creased toolperformance, and increased maintenance, and may invalidate all warranties.Repairs should be made only by authorised trained personnel. Consult your nearest Ingersoll-Rand Au tho rised Servicenter.

DANGER

WARNING

CAUTION

NOTICE

NOTICE

NOTICE

WARNING

GB

16

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

WARNING LABEL IDENTIFICATION

SPECIFIC WARNINGS

• When wearing gloves and operating models with in side trigger, always be sure that the gloves will not pre vent the trigger from being released.

• Wear safety shoes, hard hat, safety goggles, gloves, dust mask and any other appropriate pro tec tive cloth-ing while operating the tool.

• Do not indulge in horseplay. Distraction can cause ac ci-dents.

• Keep hands and fi ngers away from the throt tle lever until it is time to operate the tool.

• Never rest the tool or chisel on your foot.• Never point the tool at anyone.• Compressed air is dangerous. Never point an air hose

at yourself or co–workers.• Never blow clothes free of dust with com pressed air.• Be sure all hose connections are tight. A loose hose not

only leaks but can come completely off the tool and while whipping under pressure, can injure the operator and others in the area. At tach safety cables to all hoses to prevent injury in case a hose is accidentally broken.

• Never disconnect a pressurised air hose. Al ways turn off the air supply and bleed the tool be fore dis con nect ing a hose.

• The operator must keep limbs and body clear of the

chisel. If a chisel breaks, the tool with the bro ken chisel projecting from the tool will sud den ly surge forward.

• Do not ride the tool with one leg over the han dle. In ju ry can result if the chisel breaks while riding the tool.

• Know what is underneath the material being worked. Be alert for hidden water, gas, sewer, tele phone or elec-tric lines.

• Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet cur rent safety and health standards. Use cleaning sol vents in a well-ven-ti lat ed area.

• Do not fl ush the tool or clean any parts with die sel fuel. Diesel fuel residue will ignite in the tool when the tool is operated, causing damage to in ter nal parts. When us-ing models with outside triggers or throttle levers, take care when set ting the tool down to prevent ac ci den tal op er a tion.

• Do not operate the tool with broken or dam aged parts.

• Never start the tool when it is lying on the ground.• This tool is not designed for working in ex plo sive at mo-

spheres.• This tool is not insulated against elec tric shock.

WARNING

WARNINGAlways wear eye protectionwhen operating or perfomingmaintenance on this tool.

WARNINGAlways wear hearingprotection when operatingthis tool.

OFF

ON

WARNINGAlways turn off the air supply and disconnect the airsupply hose before installing,removing or adjusting anyaccessory on this tool, or before performing any maintenance on this tool.

WARNINGDo not use damaged, frayedor deterlorated air hosesand fittings.

Air powered tools can vibratein use. Vibration, repetitivemotions or unfocomfortable po-sitions may be harmful to yourhands and arms. Stop usingany tool is discomfort, tinglingfeelingor pain occurs. Seekmedical advice before resum-ing use

WARNING WARNINGDo not carry the tool bythe hose.

Keep body stance balancedand firm. Do not overreachwhen operating this tool.

WARNING

103 psig(7.0 bar/700kPa)

WARNINGOperate at 103 psig(7.0 bar/700 kPa Maximumair pressure)

GB

17

PLACING TOOL IN SERVICELUBRICATION

Protec Engine Oil

Always use an air line lubricator with these tools. We rec om mend the following Lubricator–Unit and Lubricant:

In Line Lubricator: CPN: 35371111Lubricant: Protec Engine Oil CPN: 85448405

Attach the lubricator as close to the tool as prac ti cal.

After each two or three hours of operation and at the be-gin ning of each work shift, if an air line lu bri ca tor is not used, disconnect the air hose and pour about 3 cc of oil into the air inlet of the tool.

Before storing the tool or if the tool is to be idle for a period exceeding twenty-four hours, pour about 3 cc of oil into the air inlet and operate the tool for 5 sec onds to coat the in ter-nal parts with oil.

INSTALLATION

Air Supply and Connections

Always use clean, dry lubricated air. Dust, corrosive fumes and/or excessive moisture can ruin the motor of an air tool. An air line fi lter can greatly increase the life of an air tool. The fi lter removes dust and moisture.

Make sure all hoses and fi ttings are the correct size and are tightly secured. See diagram PP1 for a typ i cal piping ar range ment.

The tool is shipped from the factory with 3/4” NPT male inlet thread and quick release coupling.

OPERATION

Accessory Installation

Always turn off the air supply and disconnect the air supply hose before installing, re mov ing or ad just ing any accessory on this tool or before performing any maintenance on this tool. Failure to do so could result in injury.For Screw – on type Retainer1. Grasp the Retainer and unscrew from the Barel.2. Insert the accessory through the Retainer Assembly and

install it on the tool. Screw the Retainer onto the barrel until you feel the Retainer O-ring drop into the groove in the Retainer.

For Latch Type Retainer 1. Operate the Latch until it is approximately 90 de grees

to the body of the tool and clicks into po si tion.2. Insert the accessory into the tool until the collar of the

accessory is past the Latch.3. Operate the Latch until it is parallel to the tool and it

clicks into position.

Do not repair the tool at the work site. Always takethe tool to a repair shop. Never drag the tool on theground. The air port and other openings will become clogged with dirt and debris.

Compressed air is dangerous. When blowing the line clear of dirt, wear eye protection and keep the air line directed to ward a safe, clear area.

Always blow out the air line before using to clear the line of dirt.

Do not operate the tool unless the chisel is againstthe work since this will cause premature wear ofparts and reduce the vibration isolation propertiesof the tool.

Always break material to the point of “give.” Crack ing does not result in a complete break. Clear away rubble as it is broken since uncleared rubble blocks the point of “give.”

Always take the right size “bite” with the tool. When work ing new material, experiment to fi nd the right size “bite” re quired for breaking that material ef fi cient ly.

If “bites” are too big, the operator will try to pry with the tool. This could break the chisel. The tool is de-signed for demolition, not pry ing. Always use a pick for prying. If “bites” are to small, the operator will be working too slow ly.If the chisel or accessory should become stuck, do not use excessive force or mechanical means on the tool to pull out the chisel. Doing so will damage the vibration isolation unit. Break out the stuck chisel with a spare chisel or tool.

Diagram PP1

WARNING

NOTICE

CAUTION

CAUTION

NOTICE

GB

51

GENERAL INSTRUCTIONS• Clean the Pickhammer outer surface.• Do not disassemble the pickhammer any further than

necessary to replace or repair damaged or worn parts.• Whenever grasping a pickhammer 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 fi t in or on a sub-assembly unless the removal of the part is necessary for repairs or replacement.

• Do not disassemble the pickhammer unless a complete set of O-rings is available for replacement.

DISASSEMBLY OF THE FRONTHEADScrew retainer modelsUnscrew retainer (12) off the cylinder (1) and remove chisel buffer (13) from inside retainer. Remove seal ring (8) from its groove in the cylinder.Latch retainer modelsRemove nut (17) and fronthead pinch bolt (16) from the fron-thead (15). Lightly tap the fronthead (using a hide mallet if necessary) off the cylinder (1).Press or drift out the two fronthead spring pins (18, 19) and remove the latch lever (20).The plunger (22) and plunger spring (21) can be removed from the fronthead.

MAIN DISASSEMBLYGrip handle body casting (24) fi rmly in a vice (use leather or copper covered vice jaws).Insert three or four pieces of thin sheet steel approximately 8mm wide up into the muffl er and beneath the retaining lip of the muffl er moulding (9) from the handle end of the cylin-der. This will allow the rubber retaining lip of the muffl er to slide along past the groove in the cylinder nut (11) and make removal of the muffl er easier. Note that the bearing sleeve and muffl er are removed together. Slide muffl er (9) and bearing sleeve (10) off over the cylinder assembly (1). Use a small screwdriver to disengage the end of the locking ring (40) from the hole in the cylinder nut (11). Rotate the locking ring in its groove a little to prevent re-locking. (Re-moval of the locking ring is not necessary unless replacement is required.)Use a large spanner (75 mm) across the fl ats of the cylinder nut (11) and unscrew the nut from the cylinder assembly. Remove the anti-rotation key (7) from its slot in the handle body (24). The key is provided with an M5 tapped hole to aid removal by a jacking screw if nessesary.The cylinder assembly (1) may now be slid from the handle assembly (23), take care to prevent loss of the cylinder spring (6) and o-ring (38).

HANDLE DISASSEMBLYGrip handle body (24) in a vice (use leather or copper covered vice jaws).Unscrew throttle valve plug (29) using a 13 mm spanner.Withdraw throttle valve spring (28), throttle valve ball (27) and throttle valve plunger (26).Remove the throttle lever (25) by pressing or drifting out spring pin (26).Unscrew quick release coupling (31) from inlet bushing (30). The inlet bushing (30) can be removed if required though it is assembled into the handle using a high strength retainer and disassembly is not normally necessary.

CYLINDER DISASSEMBLYNote: The cylinder assembly should not be disassem-bled unless there is evidence of excessive wear of the piston striking face, or evidence of excessive wear of the cylinder (1) bore, cushion bore or piston (3) di-ameters. Physical inspection of the above parts will require a new cylinder plug (6) and all O-rings to be available for re-assembly.

Tests to estimate wear in cylinder assembly components.

First thoroughly clean and degrease the whole cylinder assembly inside and out and blow dry. – Caution: wear su-itable personal protection, barrier cream, gloves and eye protection. Read any instructions and warnings specifi c to the degreasing agent.

• Piston striking face. If an indent caused by chisel contact, of approximately

0.5mm deep can be felt in the piston striking face – replace the piston.

• Cushion wear. (Test dry without oil) Hold the cylinder so the piston slides fully towards the

valve end. Quickly invert and bring the cylinder vertical allowing the piston to fall towards the retainer end. If a metal to metal noise can be heard at the end of the piston stroke an air cushion is not present and a new cylinder assembly (1) and /or piston (3) may be required.

Note: Continued use of the hammer with insuffi cient cushion will result in premature cylinder failure.

• Cylinder bore or piston diameter wear. Wear affecting these parts may have occurred if low hit-

ting power is reported. First ensure all airways into, and out from exhaust ports

including muffl er of tool are clear. Disassembly and precise measurement of the diameters will be required to confi rm wear.

DisassemblyGrip the cylinder (1) horizontally in a vice (use leather or copper covered vice jaws).Insert a mild steel bar of approx 20mm diameter by 300mm long into the nozzle end of the cylinder and using a copper mallet drive out the cylinder plug (5) with the piston (3).

Note: The cylinder plug (6) is non metallic and is retained by a lip which will be destroyed when removed in this man-ner.

Caution:Wear suitable eye protection, and be aware that the piston may be ejected or fall and cause injury.

The valve ring (4) may be removed by gently opening at the split and sliding the ring over the end of the cylinder.

Note: Take care not to stretch the ring.Remove O-rings (38 may stick in handle body), (37), (36), and (39).The nozzle (2) is pressed into the cylinder and retained with Loctite 601 – do not disassemble unless replacement is necessary.The cylinder plugs (35) should not be removed, however check that they are present.Inspect valve spring pins (33) and (34) for signs of wear and security.

DISASSEMBLING THE IR10PV AND IR12PV PICKHAMMERS

52

ASSEMBLY OF THE IR10PV AND IR12PV PICKHAMMERSGENERAL 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 thin fi lm of O-ring lubricant to all O-rings before fi nal assembly.

· It is recommended that the assembly of the nozzle (2) be carried out by the manufacturer or authorised distribu-tor.

· The existence of a piston air cushion should be determi-ned. Hold the cylinder vertically and allow the piston to drop down the bore small diameter fi rst. An air cushion is present if the piston “bounces”, at the bottom of the cylinder and no metal to metal contact noise can be he-ard. If a cushion is not present contact your authorised Ingersoll – Rand repair centre for advice.

CYLINDER ASSEMBLYGrip the cylinder (1) vertically nozzle down, in a vice protected with leather or copper covered vice jaws.If the cylinder has been disassembled completely rebuild in the following order.Lubricate and insert the piston (3) small end fi rst into the bore. Locate the pilot diameter of cylinder plug (5) in cylinder bore and gently tap home using a hide mallet.Gently spread apart the ends and slide valve ring (4) onto the cylinder. Locate the split around the valve spring pins (33) and (34).Lubricate and replace the O-rings (37) & (36) in their gro-oves.

HANDLE ASSEMBLYPosition throttle lever (25) in its slot in the handle casting and align the holes in each part.Drift or press home the spring pin (26). Check the throttle lever is free to move easily.Grip the handle casting (24) in a vice protected with leather or copper covered vice jaws.Lubricate and insert throttle valve plunger (26) into position reduced diameter out of the hole.Replace the throttle valve ball (27) and spring (28) and retain in place with throttle valve plug (29), apply loctite 243 to the threads of the plug and screw home fully.If the air inlet (30) has been removed, refi t it into the handle casting using Loctite 243 and screw home fully.Replace the quick release coupling (31).

MAIN ASSEMBLY Firmly grip the handle assembly (23) vertically in a vice (protected with leather or copper covered vice jaws).Position the O-ring (38) and stand the cylinder spring (6) centrally at the bottom of the handle boreCarefully slide the cylinder assembly (1) into the cylinder until the key slot in the handle body (24) aligns with the mating slot in the cylinder assembly (1). Note: Take care not to dislodge the cylinder spring off its face in the handle. Lubricate the slot in the cylinder and replace the anti-rota-tion key.Note: Check the handle is free to slide on the cylinder.Remove the pickhammer from the vice.Ensure that O-ring (39) is in place on the cylinder (nozzle end).

Lower the cylinder nut (11) onto the handle and cylinder assembly, engage the handle threads of the nut and tighten by hand. Fully tighten the Cylinder nut using a (75mm) spanner until the lock hole in cylinder nut (11) aligns with a hole in the handle body.Note: Sight or feel for correct alignment with a suitably sized wire. Snap the locking ring pin in place. Slide the muffl er (9) together with bearing sleeve (10) down the cylinder until the muffl er retaining lip engages with the groove in the cylinder nut (11).

ASSEMBLY OF THE FRONTHEAD – SCREW RETAINER MODELS

Replace the sealing ring (8) in its groove in the cylinder.Inspect the chisel buffer (13) for wear and replace if necessary, by sliding a new buffer into the retainer.Note: Premature failure of the cylinder may occur if a worn chisel buffer (13) is not replaced. Ingersoll – Rand recommend that the buffer (13) is checked frequently during use and replaced if nesseary.Screw the retainer onto the cylinder assembly.

ASSEMBLY OF THE FRONTHEAD – LATCH RETAINER MODELS

Grease the latch plunger (22) and plunger spring (21) and insert them into position in the fronthead (15).Locate the latch lever (20) with the holes in the fronthead and press or drift into place the fronthead spring pins (18,19).Check the operation of the latch.Slide the fronthead (15) onto the end of the cylinder and align the bolt hole with the groove machined in the cylinder.Fit fronthead pinch bolt (16) and secure with nut (17) tighten to 90 Nm (66.4 lbs.ft) torque.

ASSEMBLY CHECKSFollowing service or repair the pickhammer should be checked for correct operation before being sent back to the job site.Fit the correct size accessory into the pickhammer and con-nect to an airline. Using low pressure 2 bar (30psi) check to ensure the pickhammer is free of air leaks around the inlet connection and also that the pickhammer does not automati-cally 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 tools starts and stops cleanly and without hesitation.Pickhammer operating frequency should be as given in the specifi cation table at the end of this manual.

53

SP

EC

IFIC

AT

ION

S F

OR

IR10

PV

AN

D IR

12P

V P

ICK

HA

MM

ER

S

Mod

elC

hu

ck S

ize

Cp

n

Ove

rall

Len

gth

mm

(in

)

Ove

rall

Wid

th

mm

(in

)W

eigh

tk

g (l

bs)

Max

Wor

kin

gP

ress

ure

bar

(p

si)

Air

Con

sum

pti

onm

3 /min

@ 6

bar

(C

FM

)

Imp

act

Fre

qu

ency

/min

IR10

PV

25

rou

nd

× 75

S

crew

8504

1986

51

6 (2

0.3)

1

90 (

7.5)

10 (

22)

7 (1

03)

1.

0 (3

5)

5.

1

2040

–

IR10

PV

22

hex

. × 8

2

Scr

ew

85

0419

94

516

(20.

3)

190

(7.

5)

10

(22

)

7

(103

)

1.0

(35)

5.1

20

40

–

IR10

PV

22

hex

. × 8

2

Lat

ch

85

0420

00

525

(20.

6)

190

(7.

5)

10

(22

)

7

(103

)

1.0

(35)

5.1

20

40

9

0 (6

6.4)

IR12

PV

25

rou

nd

× 75

S

crew

8504

2018

63

5 (2

5.0)

1

90 (

7.5)

1

2 (2

6.5)

7 (1

03)

0.

9 (3

2)

3.

8

1260

–

IR12

PV

22

hex

. × 8

2

Scr

ew

85

0420

26

635

(25.

0)

190

(7.

5)

12

(26.

5)

7

(103

)

0.9

(32)

3.8

12

60

–

IR12

PV

22

hex

. × 8

2

Lat

ch

85

0420

34

644

(25.

3)

190

(7.

5)

12

(26.

5)

7

(103

)

0.9

(32)

3.8

12

60

9

0 (6

6.4)

Ret

ain

erT

ype

Fro

nth

ead

Nu

tT

orq

ue

Nm

(ft

.lb

s)

Cer

tifi

edV

ibra

tion

Lev

el m

/s2

@ 6

bar

54

PAR

TS

LIS

T

Ref

.P

art

Nam

eQ

uan

tity

Cp

n I

R10

PV

I

R12

PV

Ref

.P

art

Nam

eQ

uan

tity

Cp

nIR

10P

V

I

R12

PV

1C

ylin

der

Ass

embl

y (2

2 H

ex x

82

noz

zle)

Lat

ch m

odel

185

0424

7085

0425

8833

Val

ve s

prin

g p

in o

ute

r1

8504

2836

8504

2836

1C

ylin

der

Ass

embl

y (2

2 H

ex x

82

noz

zle)

Scr

ew m

odel

185

0425

9685

0426

0434

Val

ve s

prin

g pi

n in

ner

185

0428

4485

0428

441

Cyl

inde

r A

ssem

bly

(25

Rou

nd

x 75

noz

zle)

Scr

ew m

ode

185

0426

1285

0426

2035

Plu

g2

8504

2851

8504

2851

2N

ozzl

e 22

hex

x 8

21

8504

2638

8504

2638

36O

-rin

g1

8504

2869

8504

2869

2N

ozzl

e 25

rou

nd

x 75

185

0426

4685

0426

4637

O-r

ing

185

0428

7785

0428

7738

O-r

ing

185

0428

8585

0428

853

Pis

ton

185

0426

5385

0426

6139

O-r

ing

185

0428

9385

0428

934

Val

ve R

ing

185

0426

7985

0426

7940

Loc

k ri

ng

185

0429

0185

0429

015

Cyl

inde

r pl

ug

185

0426

8785

0426

956

Cyl

inde

r sp

rin

g1

8504

2703

8504

2703

7 A

nti

-rot

atio

n k

ey1

8504

2711

8504

2711

8S

eali

ng

rin

g (N

ot fi

tted

to

Lat

ch r

etai

ner

mod

els)

185

0427

2985

0427

2941

Lat

ch K

it

185

0413

0985

0413

099

Mu

ffl e

r1

8504

2737

8504

2745

16F

ron

thea

d S

crew

185

0409

9685

0409

9610

Bea

rin

g sl

eeve

185

0427

5285

0427

6017

Fro

nth

ead

Nu

t1

8504

1010

8504

1010

11C

ylin

der

nu

t1

8504

2778

8504

2778

18F

ron

thea

d S

prin

g P

in I

nn

er1

8504

0954

8504

0954

12S

crew

fro

nth

ead

185

0427

8685

0427

8619

Fro

nth

ead

Spr

ing

Pin

Ou

ter

185

0409

7085

0409

7013

Ch

isel

bu

ffer

185

0422

1685

0422

1620

Lat

ch1

8504

0731

8504

0731

14L

atch

Fro

nth

ead

Ass

embl

y1

8504

0624

8504

0624

21P

lun

ger

Spr

ing

185

0409

4785

0409

4715

Lat

ch F

ron

thea

d1

8504

0632

8504

0632

22P

lun

ger

185

0409

2185

0409

2116

Fro

nth

ead

Scr

ew1

8504

0996

8504

0996

17F

ron

thea

d N

ut

185

0410

1085

0410

1018

Fro

nth

ead

Spr

ing

Pin

In

ner

185

0409

5485

0409

5419

Fro

nth

ead

Spr

ing

Pin

Ou

ter

185

0409

7085

0409

7020

Lat

ch1

8504

0731

8504

0731

21P

lun

ger

Spr

ing

185

0409

4785

0409

47It

ems

not

illu

stra

ted

22P

lun

ger

185

0409

2185

0409

2152

*N

oise

Sti

cker

107

185

0402

10–

23H

andl

e A

ssem

bly

185

0427

9485

0427

9452

*N

oise

Sti

cker

105

1–

8504

2562

24H

andl

e B

ody

185

0428

0285

0428

0253

*W

arm

ing

Sti

cker

185

0402

0285

0402

0225

Tri

gger

185

0422

4085

0422

4054

*W

arra

nty

car

d1

8504

0285

8504

0285

26T

rigg

er P

in1

8504

2257

8504

2257

55*

Box

Lab

el E

U1

8504

2299

8504

2299

27T

rigg

er B

all

185

0422

6585

0422

6556

*B

ox L

abel

US

A1

8504

2307

8504

2307

28T

rigg

er S

prin

g1

8504

2273

8504

2273

57*

Box

185

0423

1585

0423

1529

Th

rott

le v

alve

plu

g1

8504

2810

8504

2810

58*

Box

inse

rt (

fron

thea

d)1

8504

2323

8504

2323

30In

let

Bu

shin

g1

8504

0897

8504

0897

59*

Box

inse

rt (

han

dle)

185

0429

1985

0429

1931

Qu

ick

Cou

plin

g E

U1

8504

0905

8504

0905

60*

Op

& m

ain

t. m

anu

al I

R10

PV

& I

R12

PV

185

0429

2785

0429

2731

Qu

ick

Cou

plin

g U

SA

185

0409

1385

0409

1361

*N

ame

plat

e st

icke

r1

8504

2935

8504

2935

32T

hro

ttle

pin

185

0428

2885

0428

2869

*In

lin

e lu

bric

ator

135

3711

1135

3711

1170

*P

rote

c E

ngi

ne

oil 5

l1

8544

8405

8544

8405

(Ite

ms

mar

ked*

not

illu

stra

ted)

55

3940

119

10

1615

17

18 19 22 2120

14

738

65

374

36

3

813

122

2625

24

23

30 31

32

2728

29

3430

35

12

41

16

17

19

2122

2018

www.portablepower.irco.com

Ingersoll – Rand CompanyPortable Power Division P.O. Box 868501 Sandford AvenueMocksville,North Carolina 27028USA

Ingersoll – Rand Company LtdPortable Power Division

Swan LaneHindley Green

Wigan WN2 4EZUnited Kingdom