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A1

INTRODUCTION

9803/1250

A1

Issue 2

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, gaskets 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

BREAKER MODEL AND SERIAL 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

HM 22

6

HM 25

7

HM 29

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.

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.

c

20LPM AT 138 BAR
ETHMA CATEGORY

D

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

Summary of Contents for 929/05400

Page 1: ...T 717370 717370 SERVICE MANUAL 9803 1250 ISSUE 2 MAY 04 PRINTED IN ENGLAND SERVICE MANUAL JCB HAND HELD HYDRAULIC EQUIPMENT 9803 1250 ISSUE 2 9803 1250 JCB Attachments Riverside Rugeley Staffordshire WS15 2WA England Tel 01889 572700 ...

Page 2: ...OWERPACKS Section E 9803 1250 Issue 2 CONTENTS 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 ...

Page 3: ... 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 ...

Page 4: ...pscrews Standard 20kg 23kg 26 kg 67 6 8 50 Top cover to Handle bracket capscrews Vibro 22kg 25kg 28 kg 16 1 6 11 9 Top cover to Handle bracket capscrews HM22 HM25 HM29 16 1 6 11 9 Barrel to nose capscrews Standard 20 23 kg Vibro 22 25kg 135 13 8 100 M12 Barrel to nose capscrews HM22 HM25 135 13 8 100 M12 Barrel to nose capscrews Standard 26 kg Vibro 28 kg 215 21 9 158 M14 Barrel to nose capscrews ...

Page 5: ...nd 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 cl...

Page 6: ...dismantling HM22 25 29 B3 Breaker inspection HM22 25 29 B6 Breaker assembly HM22 25 29 B8 Charging the accumulator B11 Equipment required Charging pressure Charging procedure Fault Finding B12 Specifications HM22 25 29 B12 Exploded View HM26 Non EU B13 Servicing HM26 Non EU B14 Exploded View HM22 25 29 B15 NOTE SEE SECTION C FOR MAINTENANCE OF BREAKERS OTHER THAN HM22 25 OR 29 ...

Page 7: ...inants 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 d Never use pe...

Page 8: ...maintenance checks must be rectified before the equipment is used 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 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 ...

Page 9: ... for oil spillage and remove the two upper barrel fixing capscrews Remove the barrel A A A 3 Before commencing dismantling clean externally Remove the hoses Remove the two lower barrel fixing capscrews Separate the barrel A from the nose B B B A A 1 Using a press remove roll pins Q from the nose This releases latch R latch plunger S and the plunger spring S S O O R R 2 Unless signs of damage or we...

Page 10: ...ool H from the head J 12 Remove vibration dampening springs 11 Unscrew the handle pivot pin Z nearest the trigger pin Withdraw handles assemblies from the handles control bracket Z Z Z Z G G J J H H 10 Remove screws 4 off each cover from covers N 2 off this will expose the handle mechanism N N 9 Remove the plug K seal washer L spring and trigger spool M from the head J Examine seals on the head J ...

Page 11: ... gas to escape Refit the cover screw T 15 When you are sure that all the gas in the accumulator has been evacuated remove the safety screw V from the head 16 Remove the four top cover retaining screws P and remove the cover Note There are two long and two shorter retaining screws 18 Remove the diaphragm X from the head X X 17 Remove the trigger pin W and the O ring seal Y from the head W W Y Y P P...

Page 12: ...r D replace if necessary 3 Examine the check valve ball F and ball seats for signs of damage or excessive wear Obtain new components if necessary 4 Examine the seals for signs of wear Pay particular attention to their lips Obtain new seals if necessary or if the piston is changed 5 Examine the housing cap G and spool H for signs of damage Obtain new components if necessary 6 Examine the plug K sea...

Page 13: ...he 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 10 Check the spring ring aa guide rings ff 2 off carrier ii spring jj and tool bush nn for damage and wear Replace as necessary See Note below 11 Examine the diaphragm X for signs of damage Pay particular attention for signs of cracking around the diaph...

Page 14: ...K into the head J Fit seal on head unit J 3 Fit the trigger pin O into the handle bracket Fit the handle bracket to the head Treat the threads of the safety screw V with Loctite 270 and fit to the head 4 Fit the handle assembly springs Coat the contacting surface of the handle furthest from the trigger pin see item 5 and fit to the handle bracket 5 The illustration above shows the trigger handle a...

Page 15: ...using seal G into the head J Fit a new O ring to the housing seal G 9 Assemble the seals into the lower section of the barrel casting A Ensure seal ss has the open face uppermost seal zz is fitted in the same direction 10 Treat the threads E of the check valve with Loctite 542 Ensure that the ball F is clean and undamaged Obtain a new seal Assemble the check valve 11 Fit the check valve into the b...

Page 16: ...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 15 Replace covers N 2 off A A B B D D C C A A A A B B N N B10 ...

Page 17: ... 3000 lbf in2 together with female coupling JCB part no 929 06303 CHARGING PRESSURE The charging pressure should not exceed 50 bar 800 lbf in2 Refer to Specification section for specific accumulator pressures CHARGING PROCEDURE 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 ...

Page 18: ...t the flow rate is between 18 22 l min 3 96 4 84 gal min Note For HM29 30 litre flow rate 28 32l min 6 16 7 04 gal min Cold oil Warm up the oil supply Optimum temperature 20 70C 68 158F High return line back pressure Check return line back pressure Pressure should not exceed 12 bar 174 lbf in2 Incorrect oil Use only JCB Hydraulic Oil HP32 part no 4002 1000 Breaker runs hot Inadequate cooling of Ch...

Page 19: ...B13 MAINTENANCE 9803 1250 B13 Issue 1 BREAKER HM26 NON EU ...

Page 20: ... 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 ...

Page 21: ...B15 MAINTENANCE 9803 1250 B15 Issue 1 BREAKER HM22 25 29 ...

Page 22: ...reaker inspection Standard and Vibro damped C5 Breaker assembly Standard and Vibro damped C7 Breaker dismantling D and T picks C8 Breaker inspection D and T picks C14 Breaker D and T picks C16 Charging the accumulator C19 Equipment required Charging pressure Charging procedure Fault Finding C20 ...

Page 23: ...dicated the following instructions apply to both the standard handle and vibro handle type breakers 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 WARNING The breaker must be disconnected from its source of hydraulic power before any maintenanc...

Page 24: ... the head J 10 For standard handle breakers only Using a press remove roll pins N from the top cover and remove the trigger Withdraw the trigger pin O 7 Remove the seals from the lower section of the barrel casting A slide hammer will be necessary to remove the seal housing 9 Remove the plug K seal washer L spring and trigger spool M from the head 11 For standard handle breakers only remove the ca...

Page 25: ... 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 13 For vibro damped handle breakers only unscrew the han...

Page 26: ...e head 21 For vibro damped handle breakers only withdraw the trigger pin O Remove the four capscrews and remove the handle bracket from the head 18 For standard handle breakers only when you are sure that all the gas in the accumulator has been evacuated remove the safety screw V from the head 20 For vibro damped handle breakers only when you are sure that all the gas in the accumulator has been e...

Page 27: ...ps Obtain new seals if necessary 5 For standard handle breakers only examine the rubber bushes inside the handles for signs of damage Fit new bushes if necessary These bushes are a press fit inside the handles and can be removed by slitting their cores from the inside and driving out 2 Examine the check valve ball F and ball seats for signs of damage or excessive wear Obtain new components if nece...

Page 28: ...ew components if necessary 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 top of the housing using a suitable hydraulic press of approximately 20 tonnes 8 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 ...

Page 29: ...rews Torque tighten the capscrews progressively see Introduction section ensuring theat the trigger pin remains free to move 1 Place diaphragm X into the head ensuring that the diaphragm insert is uppermost as shown above Fit new O ring seal Y 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 5 For vibro damper ha...

Page 30: ...ndle breaker only fit the handles to the top cover with capscrews Torque tighten the capscrews see Introduction section 7 For vibro damped handle breakers only fit the 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 9 For vibro damped handle breakers only assemble the top cover onto the handle ...

Page 31: ...e the head assembly onto the barrel nose assembly and fit the capscrews Torque tighten the capscrews progressively see Introduction 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 13 Treat the thread of check valve E with Loctite 542 Fit the check valve an...

Page 32: ...tie securing the hose gaiter 1 and remove the gaiter Remove the hoses 2 from the adaptors 3 Remove the adaptors and seals 4 from the accumulator assembly 4 If necessary drift out the pivot pin 7 and remove the trigger 8 from the handle WARNING The pick must be disconnected from its source of hydraulic power and the oil drainer before any maintenance is carried out WARNING Under no circumstances sh...

Page 33: ...ve capscrews 28 to separate the accumulator assembly from the barrel nose assembly 7 T Type only If necessary remove roll pins 18 and 19 suing a press Remove the latch 20 plunger 21 and spring 22 9 Apply light pressure to the top of slide rail 24 to compress spring 25 then swing the bottom of the slide rail clear of bump stop 26 Remove the slide rail and the spring Repeat for the other side 11 Tur...

Page 34: ...om 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 Tighten the charging screw approximately 3 or 4 turns Refit the cover screw 15 Hold the barrel nose assembly above the workbench with the check valve housing pointing downwards Remove the che...

Page 35: ...ws 48 from the lower end of the barrel 49 one each side 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 18 Clamp the barrel nose assembly in a vice and unscrew the now 50 from the barrel 49 using a C spanner ...

Page 36: ...eck valve 43 for signs of damage or excessive wear Obtain new components if necessary 2 Examine the housing cap 29 and spool 32 for signs of damage Obtain new components if necessary 4 Examine the diaphragm 42 for signs of damage Pay particular attention for signs of cracking around the diaphragm insert Obtain a new diaphragm if necessary 6 Examine the piston 45 piston feeder 46 and barrel 49 Smal...

Page 37: ...INSPECTION D and T PICKS cont d 7 Examine slide rails 24 and springs 25 for signs of excessive wear damage or deformation Replace if necessary 8 Examine slide bearings 26 and bump stops 27 for signs of damage or excessive wear Replace if necessary ...

Page 38: ...vice Apply Loctite 242 to nose 50 and screw into the barrel using a C spanner 4 Insert piston 45 into the upper end of barrel 49 Fit new O ring 47 to piston feeder 46 and slide the piston feeder into the piston 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 3 Apply Loctite 242 to grub screw...

Page 39: ...ide rail 24 as shown Apply light pressure to the top of the slide rail to compress the spring then swing the bottom of the slide rail over the bump stop 26 Repeat for the other side 7 Turn the accumulator assembly over Insert trigger spool 36 into accumulator assembly Fit spring 35 seal 34 and plug 33 9 Assemble the accumulator assembly onto the barrel nose assembly and fit the capscrews 28 Torque...

Page 40: ...ted to the top port of the accumulator head Fit the hose gaiter 1 and secure with a cable tie BREAKER ASSEMBLY D and T PICKS cont d 12 T Type only If dismantled fit the spring 22 plunger 21 and latch 20 into the nose latch Using a press insert roll pins 18 and 19 to secure the mechanism 14 Lubricate a new O ring 12 and feed it into the hole in the top of the accumulator assembly once inside the O ...

Page 41: ...pecification 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 Do...

Page 42: ...r lacks breaking power Insufficient available pressure Check Main Relief Valve for settings refer to Specification section Low accumulator gas pressure Re charge the accumulator as Normally associated with detailed in this section violent shaking of hoses Hexagon bush in nose casting Apply JCB Retainer High Strength loose and press back Breaker runs slow Insufficient flow Check the flow rate for s...

Page 43: ......

Page 44: ...D SPECIFICATION 9803 1250 D Issue 1 CONTENTS JCB hydraulic breakers Standard Breakers D1 Vibro damped breakers D1 D2 D and T breakers D2 Noise and vibration data D3 ...

Page 45: ...2 Hydraulic supply relief valve setting Model Nos 929 05400 05600 76 bar min Model Nos 929 07200 08200 1100 lb in2 min All models 138 bar max 2000 lb in2 max Hydraulic return line pressure 12 bar max 174 lb in2 max Breaker blow frequency 1500 blows min Breaker shank size Model No 929 05400 22 mm 7 8 in Model No 929 05600 25 mm 1 in Model No 929 07200 08200 32 mm 1 1 4 in Hydraulic supply oil type ...

Page 46: ...2 mm 1 25 in Hydraulic supply oil type JCB Special Hydraulic Oil part no 4002 0224 EHTMA Category C or D D and T BREAKERS Breaker weight Dry with hoses D Handle 12 kg 26 4 lb T Handle 14 kg 28 6 lb Breaker length D Handle 645 mm 25 4 in T Handle TBA mm TBA in Accumulator gas pressure Nitrogen 33 bar 480 lb in2 Hydraulic supply flow rate 15 20 litre min 3 3 4 5 gal min Hydraulic supply pressure ran...

Page 47: ...57 RMS Acceleration ISO EEC LWA 8662 Part 5 m s2 929 05300 Vibro Damped 111 5 5 929 05400 Standard 111 18 9 929 05500 Vibro Damped 111 5 5 929 05600 Standard 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 ...

Page 48: ...y 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 components 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 III to...

Page 49: ...the sight level gauge 3 If necessary top up the Hydraulic Oil using the filler port 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 WARNING Maintenance must only be done by ...

Page 50: ...ler 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 Checking the Electrolyte Level 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 leve...

Page 51: ...coil 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 operatin...

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