New Cover.qxd
Contents
1. 9 Finally tighten the charging screw using a 4 mm Allen key 2 and refit the cover screw 1 after applying Loctite 242 to the threads Note For D and T picks refit the accumulator assembly by carrying out Steps 11 to 17 of Breaker Assembly Seals need not be replaced providing they are serviceable 9803 1250 Issue 1 C20 MAINTENANCE C20 FAULT FINDING The remedy in certain should be carried out by your JCB Dealer Symptom Breaker fails to operate Possible Fault No flow from supply Hoses incorrectly fitted Insufficient movement of trigger spool Main spool jammed or damaged Striker piston seized Remedy Check output with flow and pressure tester Check that pressure feed is connected to top port on the breaker The trigger spool should move approx 5 mm 0 2 in Check lever mechanism Remove and check Clean all associated parts Remove and check for pick up on piston feeder or barrel Replace any damaged parts Breaker lacks breaking power Insufficient available pressure Low accumulator gas pressure Normally associated with violent shaking of hoses Hexagon bush in nose casting loose Check Main Relief Valve for settings refer to Specification section Re charge the accumulator as detailed in this section Apply JCB Retainer High Strength and press back Breaker runs slow Insufficient flow2. Cold oil High return line back pressure Incorrect oil Check the flow rate for settings refer to Specification section Warm up the oil supply Optimum temperature 20 70 C 68 158 F Check return line back pressure Pressure should not exceed 12 bar 174 Ibf in2 Use only JCB Special Hydraulic Oil part no 4002 0224 Breaker runs hot Inadequate cooling of hydraulic oil Check oil supply has adequate cooling Temperature should not exceed 80 C 176 F 9803 1250 Issue 1 9803 1250 SPECIFICATION CONTENTS JCB hydraulic breakers Standard Breakers Vibro damped breakers D and T breakers Noise and vibration data D1 D1 D2 D3 Issue 1 D1 SPECIFICATION D1 JCB HYDRAULIC BREAKERS STANDARD BREAKERS Breaker weight Model Nos 929 05400 amp 05600 20 kg 44 Ib Model Nos 929 07200 amp 08200 26 kg 57 Ib Breaker length Model Nos 929 05400 amp 05600 910 mm 36 in Model Nos 929 07200 amp 08200 1050 mm 41 in Accumulator gas pressure Nitrogen Model Nos 929 05400 amp 05600 38 bar 551 Ib in Model Nos 929 07200 amp 08200 50 bar 725 Ib in2 Hydraulic supply flow rate Model Nos 929 05400 05600 18 22 l min 3 96 4 84 gal min Model No 929 07200 18 22 I min 3 96 4 84 gal min Model No 929 08200 28 32 I min 6 20 7 00 gal min Hydraulic supply pressure range Model Nos 929 05400 amp 05600 69 86 bar 1000 1247 Ib in2 Model Nos
3. NUMBER The following breakers are covered by this manual 1 Standard handle breakers 2 Vibro damped handle breakers 3 D handle picks 4 T handle picks 5 HM22 6 HM25 7 HM29 8 HM 26 Non EU The serial number of your breaker is stamped on the breaker as shown It is important to quote the serial number when making repairs or ordering parts Identification of the serial number is the only means of ensuring that you receive the correct part for your particular breaker 743480 The JCB series of hydraulic breakers are categorized by the EHTMA as Category C or D breakers and can be safely used on any hydraulic powerpack displaying the green EHTMA C or D decals as shown below Issue 2 A2 INTRODUCTION TORQUE SETTINGS Only use the following torque settings when no setting is specified in the manual CAUTION All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced with bolts of a lesser tensile specification TABLE OF IMPORTANT TIGHTENING TORQUES Tightening Points Nm Top cover to head capscrews Standard 20 kg amp 23 kg 135 Top cover to head capscrews Standard 26 kg 215 Handle bracket to head capscrews Vibro 22 kg amp 25 kg 135 Handle bracket to head capscrews HM22 amp HM25 135 Handle bracket to head capscrews Vibro 28 kg 215 Handle bracket to head capscrews HM29 215 Handle to top cover capscrews Standard 20kg 23k
4. X from the head accumulator has been evacuated remove the safety screw V from the head 9803 1250 Issue 1 B6 MAINTENANCE B6 BREAKER INSPECTION HM 22 25 29 1 Examine the piston C piston feeder D and barrel 4 Examine the seals for signs of wear Pay A for signs of damage Small scratches can be particular attention to their lips Obtain new seals carefully removed with fine emery cloth if necessary or if the piston is changed 2 Deep grooves or signs of pick up especially on 5 Examine the housing cap G and spool H for the lower sealing portion of the piston will require signs of damage Obtain new components if replacement of the component Examine seal on necessary feeder D replace if necessary 3 Examine the check valve ball F and ball seats for 6 Examine the plug K seal washer L spring and signs of damage or excessive wear Obtain new trigger spool M for signs of damage or wear components if necessary Obtain new components if necessary 9803 1250 Issue 1 B7 MAINTENANCE B7 BREAKER INSPECTION HM 22 25 29 cont d 7 Examine the roll pins Q latch R latch plunger S 10 Check the spring ring aa guide rings ff 2 off and plunger spring for signs of damage or wear carrier ii spring jj and tool bush nn for damage Obtain new components if necessary and wear Replace as necessary See Note below 8 Should it be necessary to remove the 11 Examine the diaphragm X for signs of damage component
5. damage or excessive wear Obtain new carefully removed with fine emery cloth Deep components if necessary grooves or signs of pick up especially on the lower sealing portion of the piston will require the replacement of the component H09040 3 Examine the seals for signs of wear Pay particular 4 Examine the housing cap G and spool H for signs attention to their lips Obtain new seals if of damage Obtain new components if necessary necessary H08920 H08890 5 For standard handle breakers only examine the 6 Examine the plug K seal washer L spring and rubber bushes inside the handles for signs of trigger spool M for signs of damage or wear damage Fit new bushes if necessary These Obtain new components if necessary bushes are a press fit inside the handles and can be removed by slitting their cores from the inside and driving out 9803 1250 Issue 1 06 MAINTENANCE CE BREAKER INSPECTION STANDARD AND VIBRO DAMPED cont d Q Y 3 e D s Host00 H08960 R 7 Examine the roll pins Q latch R latch plunger S 8 and plunger spring for signs of damage or wear Obtain new components if necessary Examine the diaphragm X for signs of damage Pay particular attention for signs of cracking around the diaphragm insert Obtain a new diaphragm if necessary ZN 3 H09110 9 Examine the bush inside the nose for signs of damage or wear If it is necessary to remove the bush it can be pressed out from the
6. glass 6 Refit the filler cap Note Use only the recommended hydraulic oil Changing the Main Hydraulic Filter A WARNING Hot oil and engine components can burn you Make sure the engine is cool before doing this job 1 Prepare the Machine Position the machine on level ground Switch off the engine and allow it to cool down 2 Place a container of suitable size below the filter to catch any spilt oil 3 Remove the bolts securing the lid to the hydraulic filter housing and remove the lid 4 Lift out and dispose of the filter 5 Push the new element firmly into place in the filter housing 6 Refit the lid on the filter housing ensuring that the spring clip locates between the spigots Secure with the bolts 7 Check the hydraulic oil level Refer to Checking the Hydraulic Oil Level 44 WARNING There may be limited oil spillage when the filter is removed Clean any spillage immediately and dispose of materials in accordance with current regulations Cleaning the Cooler The oil cooler fins may be cleaned using low pressure compressed air Do not attempt to clean using a wire brush as this could damage the fins 9803 1250 Checking the Electrolyte Level 44 WARNING Battery electrolyte contains sulphuric acid It can burn you if it touches your skin or eyes Wear safety glasses and handle the battery carefully to prevent spillage 1 Prepare the Machine Position the machine on level ground Switch off the engi
7. information and the publications referred to Make sure that all of your colleagues who are concerned with lubricants read it too Hygiene JCB lubricants are not a health risk when used properly for their intended purpose However excessive or prolonged skin contact can remove the natural fats from your skin causing dryness and irritation Low viscosity oils are more likely to do this so take special care when handling used oils which may be diluted with fuel contamination Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene For details of these precautions we advise you to read the relevant publications issued by your Local Health Authority plus the following Storage Always keep lubricants out of reach of children Never store lubricants in open or unlabelled containers Handling New Oil There are no special precautions needed for the handling or use of new oil beside the normal care and hygiene practices Used Oil Used oils contain harmful contaminants Here are pre cautions to protect your health when handling used oil 1 Avoid prolonged excessive or repeated skin contact with used oil 2 Apply a barrier cream to the skin before handling used oil 3 Note the following removing oil from the skin a Wash your hands thoroughly with soap and water b Using a nail brush will help c Use special hand cleansers to help clean dirty hands
8. top of the housing using a suitable hydraulic press of approximately 20 tonnes 9803 1250 Issue 1 C7 MAINTENANCE C7 BREAKER ASSEMBLY STANDARD AND VIBRO DAMPED 44 CAUTION Before commencing assembly all components must be scrupulously cleaned A 3 1 4 Note During assembly apply Multi Gasket Loctite 574 JCB Part No 4102 1201 to all joint faces 1 Place diaphragm X into the head ensuring that the diaphragm insert is uppermost as shown above Fit new O ring seal Y H08890 Fit the trigger spool M spring seal washer L and plug K into the head H09000 For standard handle breakers only assemble the top cover onto the head and fit the four capscrews Torque tighten the capscrews progressively see Introduction section ensuring theat the trigger pin remains free to move 9803 1250 3 For standard handle breakers only insert the trigger pin O Assemble the trigger onto the top cover and fit roll pins N using a press H09061 For vibro damper handle breakers only fit the trigger pin O Assemble the handle bracket onto the head and fit the four capscrews Torque tighten the capscrews progressively see Introduction section ensuring that the trigger pin remains free to move Issue 1 C8 MAINTENANCE C8 BREAKER ASSEMBLY STANDARD AND VIBRO DAMPED cont d H08941 6 Treat thread of safety screw V with Loctite 242 7 For vibro damped handle breakers only fit the and fit
9. working to maximum efficiency it is essential that it is properly and regularly maintained in accordance with the service schedules included in this manual Badly maintained equipment can be a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the equipment in a safe and efficient working condition Any defects found during the regular routine maintenance checks must be rectified before the equipment is used Monthly Check Breaker disconnected 1 Torque tightness of all fasteners 2 The hexagon bush in the nose casting for wear or damage 3 The cutting steel shanks for excessive wear Lubricate 1 Vibro damped handle types only Spray the trigger and all contacting parts with suitable lubricant Every 600 Operating Hours or Yearly which ever occurs first 1 Overhaul the breaker Issue 1 B3 MAINTENANCE B3 BREAKER DISMANTLING HM 22 25 29 1 Using a press remove roll pins Q from the 4 Prepare for oil spillage and remove the two upper nose This releases latch R latch plunger S and barrel fixing capscrews Remove the barrel A the plunger spring 2 Unless signs of damage or wear are evident it is 5 Push the piston C and piston feeder D out of the not necessary to remove the tool bush Removal barrel Remove 3 O rings from the barrel will be dealt with in the following Breaker Ins
10. 5 bar 800 Ibf in c Charging adaptor JCB part No 929 05800 together with 3 8 in BSP Dowty washer d Connecting hose Suitable hose of minimum operating pressure 207 bar 3000 Ibf in2 together with female coupling JCB part No 929 06303 CHARGING PRESSURE The charging pressure should not exceed 50 bar 725 Ibf in2 Refer to Specification section for specific accumulator pressures CHARGING PROCEDURE Note For D and T picks access must first be gained to the accumulator assembly by carrying out Steps 1 to 8 excluding step 7 of Breaker Dismantling 1 Remove the slotted cover screw 1 from the breaker 2 Using a 4 mm Allen key 2 slowly loosen the charging screw approximately 3 turns Do not remove the screw 3 Fit the 3 8 in Dowty washer to the charging adaptor C and screw into the breaker Do not overtighten hand tight is adequate 4 Ensure that the nitrogen bottle outlet pressure is at zero and then connect the charging hose D to the charging adaptor C 5 Gradually increase the nitrogen bottle outlet pressure until the required level is reached see Specification section 6 Push in knob 6 on the charging adaptor C to engage the charging screw and tighten Do not overtighten 7 Shut the regulator valve on the nitrogen bottle and using the venting screw 7A release the trapped gas in the hose 8 Disconnect the charging hose D and unscrew the charging adaptor C from the body of the breaker
11. 80 mm 22kg 25x108 1x 41 4 106 Lwa 3 4 m s 2 C 18 22 L Min 69 86 bar 76 bar 38 bar 929 92700 730 mm 29kg 32x 160 1 114 x 61 4 108 Lwa 5 0 m s 2 C 18 22 L Min 90 110 bar 110 bar 50 bar 929 92900 730 mm 29kg 32x 160 11 4 x 61 4 110 Lwa 5 9 m s 2 D 28 32 L Min 90 110 bar 110 bar 50 bar Noise Level Standard Noise Level EC Directive 84 537 EEC Lwa Vibration Standard Vibration Weighted RMS Acceleration ISO 8662 Part 5 m s2 9803 1250 Issue 1 B13 9803 1250 MAINTENANCE BREAKER HM26 NON EU B13 Issue 1 B14 MAINTENANCE B14 BREAKER HM26 NON EU HM26 NON EU Servicing It should be noted that when servicing this breaker shown on page B12 detail for the handle only reference should be made to Section C Standard handle breakers from 9803 1250 Issue 1 The remainder of the breaker head barrel and nose sections are covered in Section B respective sections 9803 1250 Issue 1 B15 9803 1250 MAINTENANCE BREAKER HM 22 25 29 B15 Issue 1 9803 1250 MAINTENANCE CONTENTS Breaker dismantling Standard and Vibro damped Breaker inspection Standard and Vibro damped Breaker assembly Standard and Vibro damped Breaker dismantling D and T picks Breaker inspection D and T picks Breaker D and T picks Charging the accumulator Equipment required Charging pressure Charging procedure Fault Finding Ci C5 C7 C8 C14 C16 C19
12. 929 07200 amp 08200 90 110 bar 1300 1600 Ib in2 Hydraulic supply relief valve setting Model Nos 929 05400 amp 05600 76 bar min Model Nos 929 07200 amp 08200 All models Hydraulic return line pressure Breaker blow frequency Breaker shank size 1100 Ib in2 min 138 bar max 12 bar max 1500 blows min 2000 Ib in max 174 Ib in max Model No 929 05400 22 mm 7 8 in Model No 929 05600 25 mm tin Model No 929 07200 amp 08200 32 mm 1 1 4 in Hydraulic supply oil type JCB Special Hydraulic Oil part no 4002 0224 EHTMA Category C or D VIBRO DAMPED BREAKERS Breaker weight Model Nos 929 05300 amp 05500 22 kg 44 Ib Model Nos 929 07400 amp 08300 28 kg 62 Ib Breaker length Model Nos 929 05300 amp 05500 930 mm 36 in Model Nos 929 07400 amp 08300 1090 mm 43 in Accumulator gas pressure Nitrogen 50 bar 725 Ib in Hydraulic supply flow rate Model Nos 929 05300 amp 05500 18 22 l min 3 96 4 84 gal min Model No 929 07400 18 22 l min 3 96 4 84 gal min Model No 929 08300 28 32 I min 6 20 7 00 gal min 9803 1250 Issue 1 D2 SPECIFICATION D2 JCB HYDRAULIC BREAKERS cont d VIBRO DAMPED BREAKERS cont d Hydraulic supply pressure range Model Nos 929 05300 amp 05500 Model Nos 929 07400 amp 08300 Hydraulic supply relief valve setting Model Nos 929 05300 amp 05500 Model Nos 929 07400 amp 08300 All models Hydraulic return line pressure B
13. ATOR HM 22 25 29 A WARNING Use only nitrogen gas to charge the accumulators The use of any other gas can cause the accumulators to explode Remember that although nitrogen is not poisonous you can be killed by suffocation if it displaces air in your workplace Do not allow excessive quantities of nitrogen to be discharged into the atmosphere This procedure must not be carried out with the breaker or pick connected to a source of hydraulic supply During charging the breaker must be securely mounted in the upright position This prevents the breaker falling over whilst charging thereby preventing uncontrolled escape of gas EQUIPMENT REQUIRED a Nitrogen bottle Minimum residual pressure 70 bar 1000Ibf in b Regulator with contents and outlet gauge Outlet pressure should be controllable up to 55 bar 800 Ibf in c Charging adaptor JCB part no 929 05800 together with 3 8 in BSP Dowty washer d Connecting hose Suitable hose of minimum operating pressure 207 bar 3000 Ibf in2 together with female coupling JCB part no 929 06303 CHARGING PRESSURE The charging pressure should not exceed 50 bar 800 specific Ibf in2 Refer to Specification section for accumulator pressures 9803 1250 CHARGING PROCEDURE 1 Remove the slotted cover screw 1 from the breaker Using a 4 mm Allen key 2 slowly loosen the charging screw approximately 3 turns Do not remove the screw Fit the 3 8 in Dowty
14. C20 Issue 1 C1 MAINTENANCE C1 BREAKER DISMANTLING STANDARD AND VIBRO DAMPED 44 WARNING Accumulator The breaker incorporates a pressure accumulator This accumulator is pressurised even when there is no hydraulic pressure to the breaker Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death This procedure must be carried out by a qualified person Note Unless otherwise indicated the following instructions apply to both the standard handle and vibro handle type breakers 4a WARNING The breaker must be disconnected from its source of hydraulic power before any maintenance is carried out 1 Before commencing dismantling thoroughly clean all external parts 2 Remove the hoses Remove the two lower barrel fixing capscrews Separate the barrel A from the nose B 4 Prepare for oil spillage and then remove the two upper barrel fixing capscrews remove the barrel A 9803 1250 3 The lower portion of the piston C and the seal housing and seal will be exposed 5 Push the piston C and piston feeder D out of the barrel Issue 1 C2 MAINTENANCE C2 BREAKER DISMANTLING STANDARD AND VIBRO DAMPED cont d E Ho902 H08900 6 Unscrew and remove check valve E ensuring that 7 Remove the seals from the lower section of the the breaker is positioned as shown above so as to barrel casting A slide hammer will be necessary avoid losing the check valve ball F to r
15. SERVICE MANUAL LINAWdINOA INNVYUGAH G135H GNVH or TVNNVIN SDIAUSS JCB Attachments Riverside Rugeley Staffordshire WS15 2WA England i oo sar JCB HAND HELD HAHAH ur EQUIPMENT PRINTED IN ENGLAND c ANSSI 08521 2086 9803 1250 CONTENTS INTRODUCTION MAINTENANCE HM 22 25 29 MAINTENANCE OTHERS SPECIFICATION HYDRAULIC POWERPACKS 44 WARNING Study this service manual before attempting to maintain the breaker You must understand and follow the instructions in this service manual If you are unsure of anything ask your JCB dealer or employer Do not guess or you or others could be killed or seriously injured Section A Section B Section C Section D Section E Issue 2 Al INTRODUCTION A1 ABOUT THIS MANUAL To ensure that the JCB series of hydraulic breakers can be operated efficiently and safely they must be serviced and maintained regularly This manual is designed to give you a good understanding of the breaker and provide detailed maintenance information It is assumed that personnel carrying out maintenance have at least a sound knowledge of workshop practice safety procedures and general techniques associated with the repair of hydraulic equipment Details of such are therefore generally omitted from the manual the intention being to convey only the more specialised information concerning particular aspects of the breaker or component in question For example renewal of oil seals ga
16. aused by an insufficient amount of oil in the crank case The oil alert system will shut down the engine before the oil in the crankcase can fall below a safe limit If the Oil Alert system has shut down the engine then Oil Alert indicator will flash when you attempt to restart the engine If the Lombardini 15LD315 is fitted it will either be a Recoil Start Model or an Electric Start Model Recoil Start Model Pull the starter grip lightly until resistance is felt then pull briskly Do not allow the starter grip to snap back against the engine Return it gently to prevent damage Electric Start Model Do not use the electric starter for more than 5 seconds at a time If the engine fails to start release the key and wait 10 seconds before operating the starter again After starting allow the engine to idle for a few minutes then slacken the engine speed control Temperature Idling Time The following times are recommended for allowing the engine to idle when the temperatures are as indicated below 20 C 4 F 5 minutes 20 C to 10 C 4 F to 14 F 2 minutes 10 C to 5 C 14 F to 41 F 1 minute above 5 C above41 F 20 seconds 9803 1250 Issue 1
17. crews progressively see barrel Introduction section using a Gedore narrow head torque wrench part no 7200 01 Do not use a standard torque wrench fitted with a universal joint as this distorts the torque setting Q Y H09071 S R iis 16 Assemble the head assembly onto the barrel nose 17 Assemble the plunger spring plunger S and latch assembly and fit the capscrews Torque tighten R into position in the nose Using a press insert the capscrews progressively see Introduction roll pins Q to secure the mechanism section using a Gedore narrow head torque wrench part no 7200 01 see Step 14 above Fit the hoses ensuring that the hose with the female coupling is fitted to the top port of the head assembly 9803 1250 Issue 1 C10 MAINTENANCE C10 BREAKER DISMANTLING D and T PICKS 44 WARNING Accumulator The breaker incorporates a pressure accumulator This accumulator is pressurised even when there is no hydraulic pressure to the breaker Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death This procedure must be carried out by a qualified person 44 CAUTION Before commencing assembly all components must be scrupulously cleaned A 3 1 4 Note Unless otherwise indicated the following instructions apply to both the D type and T type breakers H09180 2 Cut the cable tie securing the hose gaiter 1 and remove the gaiter Remove th
18. d Never use petrol diesel fuel or paraffin for washing 9803 1250 e Avoid skin contact with oil soaked clothing f Do not keep oily rags in pockets g Wash dirty clothing before reuse h Throw away oil soaked shoes First Aid Oil Swallowing If oil is swallowed do not induce vomiting Get medical advice Eyes In the case of eye contact flush with water for 15 minutes If irritation persists get medical attention Skin In the case of excessive skin contact wash with soap and water Spillage Absorb on sand or a locally approved brand of absorbent granules Scrape up and remove to a chemical disposal area Fires Extinguish with carbon dioxide dry chemical or foam Firefighters should use self contained breathing apparatus Waste Disposal All waste products should be disposed of in accordance with the relevant regulations The collection and disposal of used oil should be in accordance with any local regulations Never pour used oil into sewers drains or on the ground Issue 1 B2 MAINTENANCE B2 SERVICE SCHEDULES 44 WARNING Maintenance work must only be done by competent personnel A 3 1 1 amp CAUTION Only use lubricants and hydraulic recommended by JCB Attachments fluids Daily Clean 1 The breaker its steels and its hoses Check Breaker disconnected 2 All hydraulic connections 3 For damage to the breaker its steels and its hoses 9803 1250 To make sure your breaker keeps
19. e Incorrect oil Inadequate cooling of Remedy Check output with flow and pressure tester Check that pressure feed is connected to top port on the breaker The trigger spool should move approx 5mm 0 2in Check lever mechanism Remove and check Clean all associated parts Remove and check for pick up on piston feeder or barrel Replace any damaged parts Check Main Relief Valve minimum setting 76 bar 1100 Ibf in for the 22 kg Breaker and 110 bar 1595 Ibf in2 for the 25 and 29 kg Breaker Re charge the accumulator Apply JCB Retainer High Strength and press back Check that the flow rate is between 18 22 I min 3 96 4 84 gal min Note For HM29 30 litre flow rate 28 32l min 6 16 7 04 gal min Warm up the oil supply Optimum temperature 20 70C 68 158F Check return line back pressure Pressure should not exceed 12 bar 174 Ibf in2 Use only JCB Hydraulic Oil HP32 part no 4002 1000 Check oil supply has adequate cooling hydraulic oil Temperature should not exceed 80C 176F Specifications Min Acc EHTMA Pressure Relief Valve Gas Model Length Weight Steel Size mm in Noise Level Vibration Catego Flow Rate Range Settings Pressure 929 92400 760 mm 25kg 32x 160 11 4 x 61 4 109 Lwa 4 0 m s 2 Cc 18 22 L Min 90 110 bar 110 bar 43 bar 929 92500 720 mm 22kg 22x 82 5 718 x 31 4 106 Lwa 3 4 m s 2 C 18 22 L Min 69 86 bar 76 bar 38 bar 929 92600 6
20. e accumulator assembly once in pivot pin 7 to secure inside the O ring will expand to fill the groove Fit the trigger pin 11 and spring 10 D type only Fit push pin 9 5 H09190 Hossan 16 Assemble the handle assembly onto the outer 17 Assemble seals 4 and adaptors 3 to the casing and fit washers 6 and capscrews 5 Note accumulator assembly Fit hoses 2 ensuring that that two of the capscrews are longer than the the hose with the female coupling is fitted to the others top port of the accumulator head Fit the hose gaiter 1 and secure with a cable tie Issue 1 C19 MAINTENANCE C19 CHARGING THE ACCUMULATOR 44 WARNING Use only nitrogen gas to charge the accumulators The use of any other gas can cause the accumulators to explode Remember that although Nitrogen is not poisonous you can be killed by suffocation if it displaces air in your workplace Do not allow excessive quantities of nitrogen to be discharged into the atmosphere This procedure must not be carried out with the breaker or pick connected to a source of hydraulic supply During charging the breaker must be securely mounted in the upright position This prevents the breaker falling over whilst charging thereby preventing uncontrolled escape of gas EQUIPMENT REQUIRED a Nitrogen bottle Minimum residual pressure 70 bar 100 Ibf in2 b Regulator with contents and outlet gauge Outlet pressure would be controllable up to 5
21. e hoses 2 from the adaptors 3 Remove the adaptors and seals 4 from the accumulator assembly H09200 4 If necessary drift out the pivot pin 7 and remove the trigger 8 from the handle 9803 1250 amp WARNING The pick must be disconnected from its source of hydraulic power and the oil drainer before any maintenance is carried out amp WARNING Under no circumstances should an attempt be made to remove the handle when the pick is connected to a source of hydraulic power 1 Disconnect hoses and collect any residual oil into a suitable container H09190 3 Remove the four capscrews 5 together with washers 6 and remove the handle assembly 5 Remove the push pin 9 D Type only Remove the spring 10 trigger pin 11 and O ring 12 from the accumulator assembly Discard the O ring Issue 1 C11 MAINTENANCE C11 BREAKER DISMANTLING D and T PICKS cont d 20 H09290 6 D Type only Remove the retainer 13 with the 7 T Type only If necessary remove roll pins 18 bump stop 14 Remove and discard O ring 15 and 19 suing a press Remove the latch 20 T Type only Remove nose latch 16 with the plunger 21 and spring 22 shim assembly 17 Remove and discard O ring _ 24 15 H09250 H09220 8 Remove the accumulator barrel nose assembly 9 Apply light pressure to the top of slide rail 24 to from the upper end of the nose casting 23 compress spring 25 then
22. ecals and their attachment points on the breaker are as shown Each decal has a part number printed on it Use this number to order a new decal from your JCB Distributor specifying the language required In addition to the decals shown in the illustration below possibly three 3 other decals may be fitted These are year model number tool size and model type They have been omitted from the illustration for clarity The model shown is an HM 25 but all other models are similar DLN 109 817 170689 9803 1250 32mm 160mm PA al Hal nag 5 a EH B 929 07255 BE fen a 743490 o m 8 pos o N o 743460 Issue 1 9803 1250 MAINTENANCE CONTENTS Lubricants Health and Safety Hygiene Storage Handling First aid Oil Fires Waste disposal Service Schedules Daily Monthly Breaker dismantling HM22 25 29 Breaker inspection HM22 25 29 Breaker assembly HM22 25 29 Charging the accumulator Equipment required Charging pressure Charging procedure Fault Finding Specifications HM22 25 29 Exploded View HM26 Non EU Servicing HM26 Non EU Exploded View HM22 25 29 NOTE SEE SECTION C FOR MAINTENANCE OF BREAKERS OTHER THAN HM22 25 OR 29 B1 B2 B3 B6 B8 B11 B12 B12 B13 B14 B15 Issue 1 B1 MAINTENANCE B1 LUBRICANTS HEALTH AND SAFETY It is most important that you read and understand this
23. emove the seal housing G H 8 Remove the housing cap G and the spool H from 9 Remove the plug K seal washer L spring and the head J trigger spool M from the head 5 H08890 H08970 10 For standard handle breakers only Using a 11 For standard handle breakers only remove the press remove roll pins N from the top cover and capscrew from inside each handle and remove remove the trigger Withdraw the trigger pin O the handles from the top cover 9803 1250 Issue 1 C3 MAINTENANCE C3 BREAKER DISMANTLING STANDARD AND VIBRO DAMPED cont d 12 For vibro damped handle breakers only remove the four top cover retaining screws P and remove the cover 14 For vibro damped handle breakers only withdraw the remaining handle assembly complete with handle pivot Remove the springs 44 WARNING Accumulator The breaker incorporates a pressure accumulator This accumulator is pressurised even when there is no hydraulic pressure to the breaker Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death Gas pressure must be released before carrying out further dismantling Note Once gas has been released a special charging tool part no 929 05800 is required to re charge the accumulator Re charging the accumulator must only be undertaken by a suitably qualified person 9803 1250 13 For vibro damped handle breakers only unscrew the handle pivot pin Z nearest the trigge
24. for signs of damage Obtain new components if signs of damage or wear Obtain new components necessary if necessary 20 D H02080 42 H02200 3 Examine the plug 33 seal 34 and trigger spool 36 4 Examine the diaphragm 42 for signs of damage for signs of damage or wear Obtain new Pay particular attention for signs of cracking ocmponents if necessary around the diaphragm insert Obtain a new diaphragm if necessary 46 E NG H09360 N3 5 Examine the check valve ball 44 and ball seat in 6 Examine the piston 45 piston feeder 46 and check valve 43 for signs of damage or excessive barrel 49 Small scratches can be carefully wear Obtain new components if necessary removed with fine emery cloth Deep grooves or signs of pick up especially on the lower sealing portion of the piston will require the replacement of the component 9803 1250 Issue 1 C15 MAINTENANCE C15 BREAKER INSPECTION D and T PICKS cont d H09310 7 Examine slide rails 24 and springs 25 for signs of 8 Examine slide bearings 26 and bump stops 27 for excessive wear damage or deformation Replace signs of damage or excessive wear Replace if if necessary necessary 9803 1250 Issue 1 C16 MAINTENANCE C16 BREAKER ASSEMBLY D and T PICKS 44 CAUTION Before commencing assembly all components must be scrupulously cleaned A 3 1 4 Note Unless otherwise indicated the following 50 instructions apply to b
25. g amp 26 kg 67 Top cover to Handle bracket capscrews Vibro 22kg 25kg amp 28 kg 16 Top cover to Handle bracket capscrews HM22 HM25 HM29 16 Barrel to nose capscrews Barrel to nose capscrews Barrel to nose capscrews Barrel to nose capscrews Standard 20 23 kg amp Vibro 22 25kg 135 HM22 amp HM25 135 Standard 26 kg amp Vibro 28 kg 215 HM29 215 pa ae ee Head assy to barrel nose assy Standard 20 kg amp Vibro 22 kg 135 Head assy to barrel nose assy HM22 135 Head assy to barrel nose assy Standard 26 kg amp Vibro 28 kg 215 Head assy to barrel nose assy HM29 215 Accumulator top to head capscrews D amp T 80 Barrel to head capscrews D amp T 135 Tightening Torques kgf m 13 8 21 9 13 8 13 8 21 9 21 9 6 8 1 6 1 6 13 8 13 8 21 9 21 9 13 8 13 8 21 9 21 9 8 1 13 8 Ibf ft 100 158 100 100 158 158 50 100 100 158 158 100 100 158 158 59 100 Capscrew Size M12 M14 M12 M12 M14 M14 M12 M12 M14 M14 M12 M12 M14 M14 M10 M12 Note Check breaker specification to match breaker weight with the model number of your breaker see Section D 9803 1250 Issue 2 A3 INTRODUCTION A3 SAFETY DECALS Decals on the breaker warn you of particular hazards Read and make sure you understand the safety message before you work with the breaker Keep all decals clean and readable Replace lost or damaged decals The d
26. h a suitable lubricant before fitting 9803 1250 Issue 1 B9 MAINTENANCE B9 BREAKER ASSEMBLY HM 22 25 29 cont d 6 Treat the thread of the pivot pin Z with Loctite 9 Assemble the seals into the lower section of the 270 and fit the pin where indicated barrel casting A Ensure seal ss has the open face uppermost seal zz is fitted in the same direction Q 7 Check that all parts of the trigger and other parts 10 Treat the threads E of the check valve with in contact are well coated with lubricant see Loctite 542 Ensure that the ball F is clean and item 5 undamaged Obtain a new seal Assemble the check valve 8 Fit the housing spool H and the housing seal G 11 Fit the check valve into the barrel A Always into the head J Fit a new O ring to the housing ensure that ball F has been fitted seal G 9803 1250 Issue 1 B10 MAINTENANCE B10 BREAKER ASSEMBLY HM 22 25 29 cont d 12 Bolt the barrel A to the nose B Torque tighten 15 Replace covers N 2 off the capscrews progressively using a Gedore narrow head torque wrench part no 7200 01 See Torque Figures on Page A2 13 Fit 3 new seals into barrel A Insert the piston C and piston feeder D into the barrel A 14 Fasten the barrel A nose B assembly onto the head assembly using the capscrews and a Gedore torque wrench part no 7200 01 See Torque Figures on Page A2 9803 1250 Issue 1 B11 MAINTENANCE B11 CHARGING THE ACCUMUL
27. heck 2 Generally for damage 3 Hydraulic oil level 4 Engine oil level 5 Hydraulic couplings 6 Hydraulic hoses Note Check the tightness of nuts bolts screws and hose fittings after the first days operation and thereafter in accordance with the Service Schedules Note The engine oil should be replaced after the first three days and thereafter in accordance with the Maintenance Schedules Every 3 Months Do the Daily jobs plus Clean 1 Air cleaner elements Refer to Engine Manufacturer s Handbook 2 Engine oil filter Change 3 Engine oil 4 Hydraulic oil filter 5 Hydraulic oil Every 6 Months Do the Daily and 3 monthly jobs plus Check 6 Tightness of nuts bolts screws and hose fittings 7 Flow and pressure output Change 8 Main hydraulic filter 9 Hydraulic oil 10 Engine oil Refer to Engine Manufacturer s Handbook Clean 11 Fuel strainer 12 Spark plug Petrol model only check plug gap Refer to Engine Manufacturer s Handbook Issue 1 E3 MAINTENANCE E3 HYDRAULIC POWERPACKS Changing the Hydraulic Oil 1 Prepare the Machine Position the machine on level ground Switch off the engine and allow it to cool down 2 Place a container of suitable size below the hydraulic tank 3 Remove the tank drain plug and filler cap to allow the oil to drain out 4 Clean and refit the drain plug 5 Pour hydraulic oil into the tank through the filler until it reaches the required level in the sight
28. l Tank at the End of each Working Day 4 Protect the Machine When not in Use Note If the machine is to be used continually at temperatures below 0 C 32 F consult your Dealer Connecting Hoses a Stop the engine b Move the Output Control to the Off position c Attach Return Line d Attach Feed Line Note The connector is locked when the collar is turned away from the ball e Start the engine and run the machine to fill up the hydraulic circuit f Check the hydraulic oil level Checking the Hydraulic Oil Level 1 Prepare the Machine Position the machine on level ground Switch off the engine and allow it to cool down 2 Check the Hydraulic Oil Level using the sight level gauge 3 If necessary top up the Hydraulic Oil using the filler port 9803 1250 Service Schedules Apart from the daily jobs the schedules are based on machine running hours Keep a regular check of hours in use Do not use a machine which is due for a regular service Rectify any defects found during regular maintenance before clearing the machine for use A WARNING Maintenance must only be done by suitably qualified and competent persons Before doing any maintenance make sure the machine is safe and correctly sited on level ground Daily 1 Clean the machine generally Clean the machine using water and or steam Do not allow mud to build up on the engine Make sure that the air inlets on the hydraulic cooler are not clogged C
29. m 8 1 kgf m 59 Ift ft 3t ts 26 F H09310 8 Slide spool 32 into spool housing Fit new O ring 9 Assemble the accumulator assembly onto the 30 to housing cap 29 and insert into accumulator barrel nose assembly and fit the capscrews 28 assembly followed by new O ring 31 Torque tighten the capscrews to 135 Nm 14 kgf m 100 Ibf ft Fit bump stops 26 to the heads of the capscrews and assemble slide bearings 27 both sides Charge the accumulator refer to page C19 H09250 10 Fit spring 25 and slide rail 24 as shown Apply light 11 Fit the accumulator barrel nose assembly into the pressure to the top of the slide rail to compress upper end of the casting 23 the spring then swing the bottom of the slide rail over the bump stop 26 Repeat for the other side 9803 1250 Issue 1 C18 MAINTENANCE C18 BREAKER ASSEMBLY D and T PICKS cont d 20 H09280 12 T Type only If dismantled fit the spring 22 13 Fit new O ring seal 15 onto the nose 52 taking plunger 21 and latch 20 into the nose latch Using care not to damage it on the exposed thread T a press insert roll pins 18 and 19 to secure the type only Fit the shim assembly 17 and the nose mechanism latch 16 D Type only Fit the bump stop 14 and the retainer 13 H09280 14 Lubricate a new O ring 12 and feed it into the 15 If dismantled fit trigger 8 to the handle and drive hole in the top of th
30. mponents are enclosed in a fully welded tubular frame which also provides easy hand holds to maximise portability A balanced lifting point is also provided This manual covers the BEAVER Ill to operate the powerpack efficiently and safely you must know the powerpack and have the skill to use it It is assumed that personnel carrying out maintenance have at least a sound knowledge of workshop practice safety procedures and general techniques associated with the repair of hydraulic equipment Note It is important to quote the serial number when making repairs or ordering parts 9803 1250 S744230 Issue 1 E2 MAINTENANCE E2 HYDRAULIC POWERPACKS MAINTENANCE Safety Decals Keep all decals clean and readable Replace lost or damaged decals Before Operating the Machine 1 Check for cleanliness 2 Check for Damage 3 Check for Leaks 4 Make sure the fuel filler cap is tightly closed 5 Check Hydraulic Oil Level 6 Ensure the machine is positioned safely 7 Ensure that all hydraulic couplings are fully servicable Refer to Hydraulic Couplings 8 Ensure that any hydraulic tools you are planning to use are compatible with the machine you are using 9 Check Engine Oil Level 10 Check the Fuel A WARNING Never refuel with the engine running Operating in Low Temperatures 1 Use the Correct Viscosity Engine Oil Refer to Engine Manufacturer s Handbook 2 Keep the Battery at Full Charge 3 Fill the Fue
31. n the charging screw approximately 3 or 4 turns Refit the cover screw l 44 s 15 Hold the barrel nose assembly above the workbench with the check valve housing pointing downwards Remove the check valve 43 with the check valve ball 44 H09360 9803 1250 12 Remove plug 33 seal 34 spring 35 and trigger spool 36 H09300 14 Dismantling the Accumulator Assembly see WARNING Remove the four capscrews 39 and separate the accumulator top 40 from the accumulator head 41 Remove the diaphragm 42 from the head H09350 47 16 Using a suitable drift push out the piston 45 and piston feeder 46 from the barrel 49 Separate the piston from the feeder Remove and discard O ring 47 Issue 1 C13 MAINTENANCE C13 BREAKER DISMANTLING D and T PICKS cont d H09380 17 Remove the two grub screws 48 from the lower 18 Clamp the barrel nose assembly in a vice and end of the barrel 49 one each side unscrew the now 50 from the barrel 49 using a C spanner 50 H09370 1 19 Remove seal 51 and seal housing 52 from the lower end of the barrel 49 Using a slide hammer remove seal 53 from seal housing 52 Discard the seals 9803 1250 Issue 1 C14 MAINTENANCE C14 BREAKER INSPECTION D and T PICKS NG 2 kalag A 1 T Type only Examine the roll pins 18 and 19 2 Examine the housing cap 29 and spool 32 for latch 20 plunger 21 and plunger spring 22
32. ne and allow it to cool down 2 Unscrew and remove the battery covers 3 Look at the level in each cell The electrolyte should be 6mm 1 4in above the plates 4 Top up if necessary with distilled or de ionised water 5 Refit the battery covers Gaining Access to Machine Components To facilitate easier maintenance the tubular frame is fitted with hinge bolts The frame may be moved to afford ready access to the machine components in the following manner 1 Remove and retain the securing clips 2 Lift the tubular frame out of the way of the machine components by hinging it on the bolts Note It is important that after maintenance the tubular frame is restored to its operating position and that the clips are securely fitted Note When the machine is to be lifted using the balanced lifting point it is important to ensure that the clips are in place and securely fitted Cleaning It is expected that components will be thoroughly cleaned and lubricated where appropiate also that any opened hose connections will be blanked to prevent entry of dirt and excessive loss of hydraulic oil Serial Numbers Serial numbers are stamped on a spacer plate located between the engine and the hydraulic tank Issue 1 E4 SPECIFICATIONS E4 HYDRAULIC POWERPACKS Engines The BEAVER Ill may be fitted with a Honda GX240 petrol engine These engines are fitted with an Oil Alert system which is designed to prevent engine damage c
33. oth the D type and T type breakers 53 Note During assembly apply Multi Gasket Loctite 574 JCB Part No 4102 1201 to all joint faces Lightly 49 lubricate all hydraulic components with hydraulic fluid prior to assembly H09370 N 1 Insert new seal 51 into the lower end of barrel 49 Assemble new seal 53 to seal carrier 52 and insert into barrel 49 Ensure the seals are fitted as shown H09380 2 Clamp the barrel 49 in a vice Apply Loctite 242 to 3 Apply Loctite 242 to grub screws 48 and fit into nose 50 and screw into the barrel using a C the lower end of barrel 49 one each side spanner NAG H09350 47 H09360 43 4 Insert piston 45 into the upper end of barrel 49 Fit 5 Treat the thread of check valve 43 with Loctite new O ring 47 to piston feeder 46 and slide the 542 Hold the barrel nose assembly above the piston feeder into the piston workbench with the check valve housing pointing downwards and fit the check valve with the check valve ball 44 9803 1250 Issue 1 C17 MAINTENANCE C17 BREAKER ASSEMBLY D and T PICKS cont d H09300 6 Fit the diaphragm 42 into the accumulator head 7 Turn the accumulator assembly over Insert 41 ensuring the diaphragm insert is uppermost trigger spool 36 into accumulator assembly Fit Assembly the accumulator top 40 onto the head spring 35 seal 34 and plug 33 and fit the four capscrews 39 Torque tighten the capscrews to 80 N
34. pection 3 Before commencing dismantling clean 6 Unscrew and remove check valve E ensuring that externally Remove the hoses Remove the two the breaker is positioned as shown above so as lower barrel fixing capscrews Separate the to avoid losing the check valve ball F barrel A from the nose B 9803 1250 Issue 1 B4 MAINTENANCE B4 BREAKER DISMANTLING HM 22 25 29 cont d barrel casting A slide hammer will be necessary 2 off this will expose the handle mechanism to remove the seal housing 8 Remove the housing cap G and the spool H from 11 Unscrew the handle pivot pin Z nearest the the head J trigger pin Withdraw handles assemblies from the handles control bracket 9 Remove the plug K seal washer L spring and 12 Remove vibration dampening springs trigger spool M from the head J Examine seals on the head J and housing cap G 9803 1250 Issue 1 BS MAINTENANCE B5 BREAKER DISMANTLING HM 22 25 29 cont d wa a way KA 13 Remove the cover screw T to expose the 16 Remove the four top cover retaining screws P charging screw and remove the cover Note There are two long and two shorter retaining screws co 14 Loosen the charging screw U slowly 17 Remove the trigger pin W and the O ring seal Y approximately 3 or 4 turns listening for all the from the head gas to escape Refit the cover screw T 15 When you are sure that all the gas in the 18 Remove the diaphragm
35. r pin Withdraw the handle assembly from the control handles bracket Pi H09100 R 15 For vibro damped handle breakers only using a press remove roll pins Q from the nose This releases latch R latch plunger S and the plunger spring 16 Remove the cover screw T to expose the charging screw Issue 1 C4 MAINTENANCE C4 BREAKER DISMANTLING STANDARD AND VIBRO DAMPED cont d H08990 H08941 17 Loosen the charging screw U slowly 18 For standard handle breakers only when you approximately 3 or 4 turns listening for all the gas are sure that all the gas in the accumulator has to escape Refit the cover screw T been evacuated remove the safety screw V from the head H09000 H09030 19 For standard handle breakers only remove the 20 For vibro damped handle breakers only when four capscrews and remove the cover from the you are sure that all the gas in the accumulator head has been evacuated remove the safety screw V from the head H08960 21 For vibro damped handle breakers only 22 Remove the diaphragm X and O ring seal Y from withdraw the trigger pin O Remove the four the head capscrews and remove the handle bracket from the head 9803 1250 Issue 1 05 MAINTENANCE C5 BREAKER INSPECTION STANDARD AND VIBRO DAMPED E HoBs00 1 Examine the piston C piston feeder D and barrel 2 Examine the check valve ball F and ball seats for A for signs of damage Small scratches can be signs of
36. rd 111 18 9 929 07400 Vibro Damped 107 5 4 929 07200 Standard 107 16 6 929 08300 Vibro Damped 108 6 0 929 08200 Standard 108 17 1 929 12900 D Type 103 5 7 929 20400 T Type 103 5 7 9803 1250 Issue 1 E1 INTRODUCTION E1 HYDRAULIC POWERPACKS The range of hydraulic powerpacks are categorised by EHTMA as Category C or D hydraulic powerpacks and can be safely used with any hydraulic tool displaying the EHTMA C or D decals as shown below 20LPM AT 138 BAR ETHMA CATEGORY 30LPM AT 138 BAR ETHMA CATEGORY TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY D POWERPACKS TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY C POWERPACKS A WARNING You must understand and follow the instructions in this manual and any accompanying manuals If you are unsure about anything ask your dealer or employer Do not guess or you or others could be killed or seriously injured GENERAL DESCRIPTION The JCB Hydraulic powerpacks have been specially developed to provide a lightweight source of portable hydraulic power for the JCB handheld hydraulic breakers and tools Despite their simple construction the powerpacks incorporate many special features such as automatic energy saving engine speed control a variable hydraulic flow and a unique hydraulic circuit design patent applied for which eliminates totally any possibility of pulsation damage to the oil cooler All the major co
37. reaker blow frequency Breaker shank size Hydraulic supply oil type EHTMA Category D and T BREAKERS Breaker weight Dry with hoses D Handle T Handle Breaker length D Handle T Handle Accumulator gas pressure Nitrogen Hydraulic supply flow rate Hydraulic supply pressure range Hydraulic supply relief valve setting Hydraulic return line pressure Breaker blow frequency Breaker shank size Hydraulic shank size ETHMA Category 9803 1250 69 86 bar 90 110 bar 76 bar min 117 bar min 138 bar max 12 bar max 1500 blows min 32 mm 1000 1247 Ib in 1300 1600 Ib in2 1100 Ib in 1700 Ib in2 min 2000 Ib in max 174 Ib in max 1 25 in JCB Special Hydraulic Oil part no 4002 0224 C or D 12 kg 14 kg 645 mm TBA mm 33 bar 15 20 litre min 50 65 bar TBA bar min TBA bar max TBA bar max 1500 blows min 2 22 mm 26 4 Ib 28 6 Ib 25 4 in TBA in 480 Ib in 3 3 4 5 gal min 725 945 Ib in2 TBA Ib in min TBA Ib in max TBA Ib in max 0 875 in JCB Special Hydraulic Oil part no 4002 0224 dor Issue 1 D3 SPECIFICATION NOISE AND VIBRATION DATA D3 Model No Handle Type Noise Level EC Vibration Weighted Directive 84 457 RMS Acceleration ISO EEC LWA 8662 Part 5 m s 929 05300 Vibro Damped 111 5 5 929 05400 Standard 111 18 9 929 05500 Vibro Damped 111 5 5 929 05600 Standa
38. s of the tool bushing firstly push in Pay particular attention for signs of cracking the spring ring aa with a sharp instrument via the around the diaphragm insert Replace as hole shown at cc necessary Note A hydraulic press will be required to remove to remove the steel tool bush nn See item 10 9 Grip the spring ring aa with a suitable pair of pincers ee and remove The sliding bush and other components can now be removed from the nose see item 10 9803 1250 Issue 1 B8 MAINTENANCE B8 BREAKER ASSEMBLY HM 22 25 29 A CAUTION Before commencing assembly all components must be scrupulously cleaned A 3 1 4 Note During assembly apply Multi Gasket Loctite 3 Fit the trigger pin O into the handle bracket Fit 518 JCB Part No 4102 1212 to all joint faces Use the handle bracket to the head Treat the threads new seals and O rings throughout of the safety screw V with Loctite 270 and fit to the head 1 Place diaphragm X into the head ensuring that 4 Fit the handle assembly springs Coat the the diaphragm insert is uppermost as shown contacting surface of the handle furthest from above Fit new O ring seal Y the trigger pin see item 5 and fit to the handle bracket mory SUID SH T pe Kg J EMPERATUNND SIZE COMPO 2 Fit the trigger spool M spring seal washer L and 5 The illustration above shows the trigger handle plug K into the head J Fit seal on head unit J after coating wit
39. skets etc and any component showing obvious signs of wear or damage is expected as a matter of course and information on these matters therefore only included where a specialised procedure or range of wear tolerances is required Similarly it is expected that components be thoroughly cleaned and lubricated where appropriate also that any opened hose connections will be blanked to prevent entry of dirt and excessive loss of hydraulic fluid For specific details regarding choice of breaker operation and choosing steels etc reference should be made to the Operator s Handbook which was supplied with the breaker USING THIS MANUAL Read this manual from front to back before attempting to maintain the breaker for the first time Particular attention must be given to all the safety aspects which are provided General safety warnings are given in this chapter and specific safety warnings are given throughout the book Read all the safety warnings regularly so you do not forget them UNITS OF MEASUREMENT The S I system is used throughout For example liquid capacities are given in litres The Imperial units are given in parentheses e g 28 litres 6 U K gal EHTMA CATEGORIZATION 20LPM AT 138 BAR ETHMA CATEGORY 30LPM AT 138 BAR ETHMA CATEGORY TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY D POWERPACKS TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY C POWERPACKS 9803 1250 BREAKER MODEL AND SERIAL
40. swing the bottom of the slide rail clear of bump stop 26 Remove the slide rail and the spring Repeat for the other side 26 H09210 H09310 10 Remove slide bearing 27 and bump stop 26 from 11 Turn the accumulator assembly over Withdraw both sides then remove capscrews 28 to separate housing cap 29 then remove and discard O ring the accumulator assembly from the barrel nose 30 Remove O ring 31 from the recess in the assembly accumulator assembly and discard the O ring Withdraw spool 32 from the spool housing 9803 1250 Issue 1 C12 MAINTENANCE C12 BREAKER DISMANTLING D and T PICKS cont d 44 WARNING Accumulator The breaker incorporates a pressure accumulator This accumulator is pressurised even when there is no hydraulic pressure to the breaker Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death Gas pressure must be released before carrying out further dismantling Note Once gas has been released a special charging tool part no 929 05800 is required to re charge the accumulator Re charging the accumulator must only be undertaken by a suitable qualified person 37 13 Releasing Gas Pressure from the accumulator Remove the cover screw 37 to gain access to the charging screw 38 Insert a 4 mm allen key and slowly loosen the charging screw approximately 3 or 4 turns listening for all the gas to escape Tighte
41. the safety screw into the head handle assembly springs Fit the handle assembly furthest from the trigger pin complete with pivot pin into the handle bracket see Step 14 of Dismantling ae H08981 8 For vibro damped handle breakers only fit the 9 For vibro damped handle breakers only remaining handle assembly Treat the thread of assemble the top cover onto the handle bracket pivot pin Z with Loctite 242 and fit the pin Spray Treat the threads of the top cover capscrews with the handles trigger and all contacting parts with a Loctite 242 and torque tighten see Introduction suitable lubricant section I H08970 10 For standard handle breaker only fit the handles 11 Fit the housing spool H and housing seal G into to the top cover with capscrews Torque tighten the head Fit a new O ring to the housing seal the capscrews see Introduction section 9803 1250 Issue 1 C9 MAINTENANCE C9 BREAKER ASSEMBLY STANDARD AND VIBRO DAMPED cont d E H08900 12 Assemble the seals into the lower section of the 13 Treat the thread of check valve E with Loctite 542 barrel casting Ensure that the open faces of the Fit the check valve and its ball F into the barrel by seals are fitted as shown on inset offering the check valve to the barrel from underneath to avoid losing the ball H09081 14 Bolt the barrel to the nose with capscrews Torque 15 Insert the piston C and piston feeder D into the tighten the caps
42. washer 5 to the charging adaptor 3 and screw into the breaker Do not overtighten hand tight is adequate Ensure that the nitrogen bottle outlet pressure is at zero and then connect the charging hose 4 to the charging adaptor 3 Gradually increase the nitrogen bottle outlet pressure until the required level is reached see Specification section Push in knob 6 on the charging adaptor 3 to engage the charging screw and tighten Do not overtighten Shut the regulator valve on the nitrogen bottle and using the venting screw 7 release the trapped gas in the hose Disconnect the charging hose 4 and unscrew the charging adaptor 3 from the body of the breaker Finally tighten the charging screw using a 4mm Allen key 2 and refit the cover screw 1 after applying Loctite 270 to the threads 743310 Issue 1 B12 MAINTENANCE B12 OPERATOR FAULT FINDING The remedy in certain cases should be carried out by your JCB dealer Symptom Breaker fails to operate Breaker lacks breaking power Breaker runs slow Breaker runs hot Possible Fault No flow from supply Hoses incorrectly fitted Insufficient movement of trigger spool Main spool jammed or damaged Striker piston seized Insufficient available pressure Low accumulator gas pressure Normally associated with violent shaking of hoses Hexagon bush in nose casting loose Insufficient flow Cold oil High return line back pressur
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