JCB Hydraulic Breakers HM012T – HM380T Service Repair Manual – PDF Download

JCB HYDRAULIC BREAKERS SERVICE MANUAL

HYDRAULIC BREAKERS (HM012T - HM380T) JCB Attachments Waterloo Park Uttoxeter Staffordshire, ST14 5PA England This manual contains original instructions verified by the manufacturer (or their authorized representative).

Important: This manual should always stay with machine

Publication No.

9813/5850-01

World Class Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section i - Front Cover

Notes:

i-0

9813/5850-01

i-0

Section i - 1 Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Units of Measurement ...........................................................................1-1 Intended use ..........................................................................................1-1 Special conditions of use .......................................................................1-1 Carrier Machine Suitability ....................................................................1-1 Machine stability ....................................................................................1-1 Setup .....................................................................................................1-1 General Description ................................................................................... 1-2 Component Identification .......................................................................1-2 Safety ........................................................................................................ 1-3 Safety - Yours and Others .....................................................................1-3 Safety Warnings ....................................................................................1-3 Safety Check List ..................................................................................1-4 Service Tools ............................................................................................. 1-7 Hose Assesories ...................................................................................1-8 Male Fitting Shown for Size Reference .................................................1-8 Nitrogen Charging Tools ........................................................................1-8 Lifting Eyes (To be sourced locally) .......................................................1-9 Nitrogen Adaptor Reference Chart .......................................................... 1-10 Maintenance Introduction .............................................................................................. 1-13 Health and Safety .................................................................................... 1-14 Safety First ..........................................................................................1-14 Lubricants ............................................................................................1-14 Wearing Parts .......................................................................................... 1-15 Lower Tool Bushing and Tools ................................................................. 1-16 Checking For Excessive Wear ............................................................1-16 Check for and Removal of Burrs .........................................................1-16 Wear Limits and Tool for Lower Tool Bushing ......................................... 1-17 Tool Retention Pin Wear Limits ...........................................................1-17 Tool Wear Limits ..................................................................................1-17 Upper Dampener Wear Limits .............................................................1-18 Lower Dampener Wear Limits .............................................................1-18 Upper Bush Wear Limits ......................................................................1-19 Bottom Bush Wear Limits ....................................................................1-19 Retainer Pin Wear Limits .....................................................................1-20 Housing Pad Wear Limits ....................................................................1-21 Adjuster Valve to Control Impact Blows ................................................... 1-22 Disassembly and Assembly Disassembly ............................................................................................ 1-23 Accumulators Discharge .....................................................................1-23 Housing (Boxed) ..................................................................................1-24 Housing (Side Plate) ...........................................................................1-26 Power Cell ...........................................................................................1-27 High Pressure Accumulator .................................................................1-34 Tool Bushes .........................................................................................1-35

i-i

i-i

Section i - 1 Contents

Contents Page No. Assembly ................................................................................................. 1-37 High Pressure Accumulator .................................................................1-37 Valve ....................................................................................................1-39 Piston Seal ..........................................................................................1-40 Tool Housing Assembly .......................................................................1-41 Cylinder ...............................................................................................1-41 Tightening Tie Rods ............................................................................1-48 Fill the Low Pressure Accumulator with Oil .........................................1-49 Gas Charging ......................................................................................1-49 Checking the low pressure accumulator .............................................1-50 Charging the High Pressure Accumulator ...........................................1-52 Conversion Table for Charging N2-Gas for the Low Pressure Accumulation (Power Cell Head) ...............................................................................1-56 Final Assembly ........................................................................................ 1-57 Installment of Power Cell into Housing ................................................1-57 Installment of Power Cell into Side Plates ...........................................1-57 Grease Charging on Models with Automatic Greasing System ..........1-58 Service Repair of Parts ......................................................................................... 1-59 Tool for Correction ...............................................................................1-59 Inspection ............................................................................................1-59 Automatic Lubrication .............................................................................. 1-64 Installation ...........................................................................................1-64 Refilling ................................................................................................1-65 Adjuster ...............................................................................................1-65 Operation .............................................................................................1-66 Installment of Tool ...............................................................................1-69 Fault Finding ............................................................................................ 1-70 Disposal of Consumable .......................................................................... 1-75 End of Life Disposal ............................................................................1-75 Specification Machine Specification .............................................................................. 1-77 Torque Settings ....................................................................................... 1-79 BSP Hose Connection .........................................................................1-79 Code 62 SAE Flange Coupling ...........................................................1-79 Part Numbers Breaker Models ....................................................................................... 1-81

i-ii

i-ii

Introduction About this Manual

Introduction About this Manual This document details the relevant use and maintenance procedures for the JCB breaker. The safety information included is directly relevant to operation and maintenance of the breaker. General safety information, and that relevant to the carrier machine is not included. For details about safe operation of the carrier machine, see the relevant documents.

Important: Do not attempt to install, operate or maintain any attachment until you have read and understood all relevant operator documentation for both the attachment, and the carrier machine. Pay particular attention to safety information. You must observe all relevant laws and regulations.

The manufacturer’s policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.

Units of Measurement In this manual, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parenthesis (), for example 28 litres (6 UK gal).

Intended use

piston strikes the tool, a strong pressure wave is generated and the breaker will be damaged.

Carrier Machine Suitability The breaker is suitable for use with the JCB JS Excavator which falls within the breakers ‘carrier weight’ of 1T-50T tonne when fitted with a high flow auxiliary/Breaker hydraulic circuit. An installation kit, suitable hanger bracket and a hose kit are available from your JCB Distributor.

The breaker is suitable for use with some other non JCB carrier machines. See the specification section for details of typical carrier requirements. Contact your JCB Distributor for advice.

Machine stability The breakers centre of gravity is considerably further away from the excavators pivot than other attachments such as a bucket. The stability chart in the excavator cab applies only to a direct vertical load on the dipper end. If the breaker is used at full reach in a near horizontal position a larger capacity machine will be required to maintain stability.

If a quick hitch is used this adds additional weight to the excavator dipper end an moves the centre of gravity of the breaker further away increasing instability.

Setup For fitment to tracked or wheeled slew type excavators for the breaking of rock shale, concrete by impact. Not for use as a lifting devise or levering

Special conditions of use

Get your JCB dealer to set up the breaker on the carrier machine. The correct flow is set by engine speed and the maximum pressure is set by the Auxiliary Releif Valve Some machines have two auxiliaries relief valves, be sure to under stand the purpose of both.

If the breaker is to be used in conditions that differ from normal breaking or demolition work conditions, such as - tunnel application, - foundry cleaning, - underwater operations, - use of special hydraulic oils, - other special conditions, it may require modifications to attachment, special operating techniques, increased maintenance or special wear items.

In case of use in special conditions, contact your JCB dealer Important: The breaker as a standard assembly must not be used under water. If water fills the space where the

1

9813/5850-01

1

Introduction General Description

General Description Component Identification HM 012T - HM 018T

HM 026T - HM 380T

A B C

D E F G

H

J

K L

M

N

P047460-88

Fig 1.

Key Components A

Tie Rod

B

Head

C

Low Pressure Accumulator

D

Cylinder Bush

E

Valve

F

Cylinder

G

Piston

H

High Pressure Accumulator

J

Tool Housing

2

K

Upper Tool Bush

L

Tool Pin

M

Lower Tool Bush

N

Tool

9813/5850-01

2

Introduction Safety

Safety Safety - Yours and Others

Safety Warnings INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them.

But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

Do not work with the machine until you are sure that you can control it.

This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators.

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

!MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

Do not start any job until you are sure that you and those around you will be safe.

!MWARNING

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.

Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

Remember

!MCAUTION

BE CAREFUL BE ALERT BE SAFE

Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

3

9813/5850-01

3

Introduction Safety

Safety Check List

Safety labels are strategically placed around the machine to remind you of possible hazards.

!MWARNING Equipment Condition Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts.

If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or place yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification.

Make sure the maintenance procedures in this manual are completed before using the equipment.

Note: The illustration(s) show a typical machine model.

Your machine may look different from the model shown.

A-1-4-1

!MWARNING Modifications and Welding The accumulator(s) in the Hammermaster are pressurised even when there is no hydraulic pressure to the breaker. Never tamper with an accumulator.

Attempting to dismantle an accumulator without first releasing the pressure can cause injury or death. Such work should only be carried out by qualified servicing personnel who have studied the relevant Service Manual.

B-1-3-7

!MWARNING Modifications and Welding Non-approved modifications can cause injury and damage. Contact your JCB dealer for advice before modifying the equipment. Before welding on the Hammermaster while it is installed on the carrier, disconnect the carrier alternator and battery. Note that electric welding of the Hammermaster tools will render them useless and make the warranty void.

Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor.

!MWARNING Manual You and others can be injured if you operate or maintain the attachment or equipment without first studying this manual. Read the safety instructions before operating the attachment or equipment. If you do not understand anything, ask your employer or JCB Dealer to explain it. Keep this manual clean and in good condition.

A-1-3-2_1

!MCAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine.

INT-1-3-3

B-1-3-2_1

!MWARNING

!MCAUTION Protect your ears. Working with the Hammermaster without wearing earmuffs can damage your hearing.

Wear earmuffs when working with the hammer.

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-5

B-2-1-13

!MWARNING Safety Labels Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown.

INT-1-3-11

4

9813/5850-01

4

Introduction Safety

!MWARNING

!MWARNING

Practise You or others can be killed or seriously injured if you do unfamiliar operations without first practising them.

Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

Prolonged running can cause hydraulic components to heat up. Skin contact with these components must be avoided.

B-1-2-18

!MCAUTION

INT-2-1-1

!MWARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing.

If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

!MWARNING

Every breaker has its own flow requirement. If the machine is not preset to deliver the correct flow for the breaker fitted, either the breaker will not function correctly or the machine may be damaged.

Whenever a breaker is fitted, it is ESSENTIAL that the engine speed is correctly preset to suit the breaker.

Have your JCB dealer reset the engine speed before using the machine with a new breaker fitted. This is a specialist job and the machine can be seriously damaged if it is not done correctly.

ATT026

Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

!MWARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.

INT-3-1-3_2

GEN-1-5_2

!MCAUTION

!MWARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves.

Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

Take care when lifting/handling.

Refer SPECIFICATION for the attachment weight.

to

B-2-1-2_2

!MCAUTION Equipment Condition Operating the equipment beyond its design limits can cause damage. It can also be dangerous.

INT-3-1-10_3

Do not operate the equipment outside its limits.

!MWARNING Hydraulic fluid at pressure can injure you. Make the machine safe before connecting/disconnecting the hoses. To do this stop the engine and then, with the starter switch 'ON', operate the carrier auxiliary circuit controls a few times to vent system pressure.

Do not try to upgrade the equipment's performance by unapproved modifications.

A-1-4-2

B-1-3-5

5

9813/5850-01

5

Introduction Safety

!MWARNING If two people are doing this job make sure that the person working the controls is a competent operator.

If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured.

B-2-1-8

!MWARNING Hydraulic oil at pressure can injure you. Make the machine safe as detailed below before removing the hose blanking plug. Follow the instructions below for connecting the hoses.

8-4-1-3

!MWARNING Before doing any routine maintenance work on the attachment while it is installed on a carrier, make the carrier safe. Stop the engine and, if appropriate, ensure that the parking brake is engaged and the drive is in neutral. Remove the starter key to prevent the engine being started.

ATT008

!MWARNING When using an attachment for example a hydraulic breaker, where the risk of flying debris is present, a protective layer or screen guard must be attached to the front of the cab to protect the operator from flying debris which could cause injury.

8-5-1-5

!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job.

Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened.

Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery.

INT-1-3-6_2

6

9813/5850-01

6

Introduction Service Tools

Service Tools The tools listed in the table are special tools required for carrying out the procedures described in this manual.

These tools are available from JCB Service.

892/00059 3/4 in BSP 892/00060 1 in BSP 332/A4825 1 1/4 in BSP

Fig 4. Male Cone Blanking Cap 816/00294 1/4 in BSP 816/00189 3/8 in BSP 816/00190 1/2 in BSP 816/00197 5/8 in BSP 816/00196 3/4 in BSP 816/00193 1 in BSP 816/80010 1 ¼ in BSP Fig 2. Pressure Test `T' Adapters 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point

A

892/00264 3/4 in BSP x 3/4 in F BSP x Test Point

B

892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00266 1 ¼ in M BSP x 1 ¼ in F BSP x Test Point 892/00267 1 1/2 in M BSP x 1 1/2 in F BSP x Test Point

P047460-84

Fig 5. Reducing Adaptor 816/20062 1 ¼ in female - 1 in male 816/90185 1 in female - ¾ in male 816/20013 1 in male - ¾ in female

Fig 3. Female Cone Blanking Cap 892/00055 1/4 in BSP 892/00056 3/8 in BSP 892/00057 1/2 in BSP 892/00058 5/8 in BSP

7

9813/5850-01

7

Introduction Service Tools Hose 3/4” straight 2150mm

615/80103

Hose 3/4” straight 2400mm

615/05100

Male Fitting Shown for Size Reference

P047460-87

Fig 6. Female Connectors 892/00279 Pressure gauge 0-400 bar (0-6000 lbf/in2) 892/00346 Pressure gauge 0-70 bar (0-1000 lbf/in2)

Dimension X (mm)

Size (inch)

20

1/2

25

3/4

30

1

892/00347 Connector 892/00254 Hose 892/00280 Pressure gauge 0-600 bar (0-9000 lbf/in2)

X

Hose Assesories Adaptors P047460-86

Fig 7.

Description

Part No.

1/2” QRC Male

45/910500

1/2” QRC Female

45/910400

Description

Part No.

1/2” Dowty seal

1406/0018

Gas charge kit

332/A2236

1/2” Adaptor

1604/0004

Nitrogen gas cylinder (3 ltr)

332/A5841

3/4” QRC Male

45/910300

Nitrogen gas cylinder (10 ltr)

332/A2258

3/4” QRC Female

45/908400

3/4” - 1/2” Adaptor

1606/0009

3/4” - 3/4” Adaptor

1604/0006

3/4” Dowty seal

1406/0021

1” QRC Male

45/910100

1” QRC Female

45/910200

1” - 3/4” Adaptor

1606/0012

1” - 1/2” Adaptor

1606/0010

1” Dowty seal

1406/0026

Nitrogen Charging Tools

Note: If the above nitrogen gas cylinder is not used, a local cylinder can be used in its place. The charging kit is equipped with a W24.32 x 14 tpi thread, if the local nitrogen cylinder is not equipped with the correct connection, an adaptor will be required. K Table 1. ( T 10)

Hoses

Description

Part No.

Hose 1/2” straight 2155mm

613/01600

Hose 1/2” straight 2250mm

613/31300

Hose 1/2” straight 2370mm

613/02200

8

9813/5850-01

8

Introduction Service Tools

Lifting Eyes (To be sourced locally)

P047460-85

Fig 8.

Size

Qty.

M10

2

M12

2

M16

2

M20

2

M24

1

M30

2

M36

2

9

9813/5850-01

9

Introduction Nitrogen Adaptor Reference Chart

Nitrogen Adaptor Reference Chart Country

Table 1.

Adaptor

Part No

Algeria

40h

892/01202

Argentina

40b

892/01196

Armenia

40n

892/01207

Australia

40b

892/01196

Austria

Direct ***

Azerbaijan

40n

892/01207

Bahamas

40b

892/01196

Bahrain

40h

892/01202

Bangladesh

40b

892/01196

Barbados

40b

892/01196

Belgium

Direct ***

Bolivia

40g

892/01201

Botswana

40b

892/01196

Brazill

40g

892/01201

Bulgaria

40n

892/01207

Burma

40b

892/01196

Canada

40c

892/01197

Chile

40g

892/01201

China

40k

892/01204

Colombia

40g

892/01201

Costa Rica

40b

892/01196

Czech Republic

Direct ***

Denmark

Direct ***

Djibouti

40h

892/01202

Dom. Republic

40g

892/01201

Ecuador

40g

892/01201

Egypt

40b

892/01196

Ethiopia

40b

892/01196

Fiji

40b

892/01196

Finland

Direct ***

France

40h

892/01202

Gabon

40h

892/01202

Gambia

40b

892/01196

Georgia

40n

892/01207

10

Country

Adaptor

Germany

Direct ***

Ghana

40b

Part No

892/01196

Greece

40h

892/01202

Guatemala

40g

892/01201

Guinea

40h

892/01202

Guyana

40g

892/01201

Honduras

40g

892/01201

Hongkong

40b

892/01196

Hungary

40h

892/01202

India

40b

892/01196

Indonesia

40b

892/01196

Iran

40h

892/01202

Iraq

40h

892/01202

Ireland

40b

892/01196

Israel

40h

892/01202

Italy

40d

892/01198

Ivory Coast

40h

892/01202

Jamaica

40b

892/01196

Japan

40e

892/01199

Jordan

40h

892/01202

Jugoslavia

40h

892/01202

Kazakhstan

40n

892/01207

Kenya

40b

892/01196

Korea

40f

892/01200

Kuwait

40h

892/01202

Kyrgyzstan

40n

892/01207

Lebanon

40h

892/01202

Libya

40h

892/01202

Lichtenstien

Direct ***

Luxembourg

Direct ***

Malawi

40b

892/01196

Malaysia

40l

892/01205

Malta

40b

892/01196

Mauritius

40h

892/01202

9813/5850-01

10

Introduction Nitrogen Adaptor Reference Chart Country

Adaptor

Part No

Country

Adaptor

Part No

Mexico

40h

892/01202

Turkey

40b

892/01196

Moldova

40n

892/01207

Turkmenistan

40n

892/01207

Morocco

40h

892/01202

Ukraine

Direct ***

Mozambique

40h

892/01202

40h

892/01202

Netherlands

Direct ***

United Arab Emirates

New Zealand

40b

892/01196

Great Britain

40b

892/01196

Nigeria

40h

892/01202

Uruguay

40g

892/01201

Norway

Direct ***

USA

40c

892/01197

Oman

40h

892/01202

Uzbekistan

40n

892/01207

40n

892/01207

Pakistan

40b

892/01196

Venezuela

Paraguay

40g

892/01201

Vietnam

40b

892/01196

Peru

40g

892/01201

Zambia

40b

892/01196

Philippines

40b

892/01196

Poland

Direct ***

Portugal

40b

892/01196

Puerto Rico

40c

892/01197

Qatar

40k

892/01204

Romania

40h

892/01202

Russ.Feder

40n

892/01207

Saudi-Arabia

40h

892/01202

Singapore

40b

892/01196

Slovakia

Direct ***

Slovenia

Direct ***

South Africa

40b

892/01196

Spain

40h

892/01202

Sri Lanka

40b

892/01196

Sudan

40b

892/01196

Surinam

40b

892/01196

Swaziland

40b

892/01196

Sweden

Direct ***

Switzerland

Direct ***

Syria

40h

892/01202

Taiwan

40b

892/01196

Tanzania

40b

892/01196

Thailand

40b

892/01196

Trinidad or Tobago 40m

892/01206

Tunisia

892/01202

11

40h

9813/5850-01

11

Introduction Nitrogen Adaptor Reference Chart

P046730-26

Fig 9.

12

9813/5850-01

12

Maintenance Introduction The outside of the breaker power cell is best cleaned with a steam cleaner, plug all open ports to prevent water and debris being forced into the internal areas.

The breaker contains compressed nitrogen gas, the high pressure ( if applicable) and low pressure accumulators must be discharged prior to disassembly). The gas charging kit part 332/A2236 will be required.

Due to the weight and difficulty of retaining the assembly during undoing fasteners, all nuts and bolts can be loosened to a nominal figure whilst the breaker is supported vertically on the support and then removed during the disassembly processes.

The tool housing should be placed over a vertical bar / tube welded to a flat plate to support the breaker during the disassembly process and of sufficient strength to resist torques applied whilst undoing the various bolts.

Powered tools may be required to undo or tighten some of the nuts and bolts.

The breaker will be full of oil, some of the oil can be drained out prior to disassembly, but it will be difficult to drain all. As its disassembled be prepared to collect the waste oil. An oil sample can be taken and the results of this will indicate any cleaning / maintanace of the carrier machines hydraulic system.

After a full service, change the carrier machines filter.

A crane and lifting slings of sufficient capacity to lift all parts is required. The various components of the power cell are tapped with metric threads to accept metric lift eyes for the assembly and disassembly process. The threads are sufficient to carry the load of the power cell.

13

9813/5850-01

13

Maintenance Health and Safety

Health and Safety Safety First

Lubricants

!MWARNING Maintenance work must only be done by competent personnel.

In the EEC all JCB lubricants are covered by individual COSHH (Control of Substances Hazardous to Health) leaflets which are available on request from your JCB Distributor.

A-3-1-1

!MWARNING

It is most important that all personnel concerned with lubricants read and understand the information contained in the relevant leaflets.

Equipment Condition Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts.

Some general guidance is given in the JCB Carrier Machine Handbook.

Make sure the maintenance procedures in this manual are completed before using the equipment.

A-1-4-1

!MWARNING Before doing any routine maintenance work on the attachment while it is installed on a carrier, make the carrier safe. Stop the engine and, if appropriate, ensure that the park brake is engaged and the drive is in neutral. Remove the starter key to prevent the engine being started.

B-3-1-2_3

14

9813/5850-01

14

Maintenance Wearing Parts

Wearing Parts The following are considered as wearing parts: - Breaker Tool - Tool Pins - Upper and Lower Bush - Seals - Tie Rods - Hoses Apart from the tie rods, inspect all the other parts weekly.

15

9813/5850-01

15

Maintenance Lower Tool Bushing and Tools

Lower Tool Bushing and Tools Checking For Excessive Wear

Check for and Removal of Burrs

1

Remove the tool as described in Tools - Installing and Removing.

1

Remove the tool as described in Tools - Installation and Removal

2

Check Bush and Tool wear limits.

2

Check for burrs on the tool shank and the retaining pin.

3

Replace the lower tool bushing as described in Lower Tool Bushing.

3

Carefully remove all burrs. Do not overheat the tool.

!MCAUTION Protect yourself when removing burrs. Wear safety glasses and industrial gloves.

B-3-1-4_1

4

16

9813/5850-01

Smear the tool shank and the bushing with JCB Extreme Hammer Grease before installing the tool.

16

Maintenance Wear Limits and Tool for Lower Tool Bushing

Wear Limits and Tool for Lower Tool Bushing Note: It is assumed that the tool has been removed. This inspection can be carried out with the bushing still in position.

Tool Wear Limits

Tool Retention Pin Wear Limits

P046730-48

Fig 11.

NEW

P046730-47

Fig 10.

NEW

WEAR LIMIT

WEAR LIMIT WEAR LIMIT (X) (Y)

mm

Inch

mm

Inch

mm

Inch

45

1.77

43

1.69

41

1.61

mm

Inch

mm

Inch

HM012T

HM012T

25

0.98

23

0.91

HM018T

57

2.24

55

2.17

53

2.09

HM018T

30

1.18

28

1.1

HM026T

70

2.76

68

2.68

66

2.6

HM026T

36

1.42

34

1.34

HM033T

75

2.95

73

2.87

71

2.8

80

3.07

78

3.07

76

2.99

HM033T

42

1.65

40

1.57

HM049T

HM049T

37.5

1.48

35.5

1.4

HM054T

90

3.46

88

3.46

86

3.39

HM054T

37.5

1.48

35.5

1.4

HM080T

95

3.74

93

3.66

91

3.58

HM080T

36

1.42

34

1.34

HM090T

105

4.13

103

4.06

101

3.98

115

4.53

113

4.45

111

4.37

HM090T

50

1.97

47

1.85

HM120T

HM120T

70

2.76

67

2.64

HM160T

135

5.31

133

5.24

131

5.16

HM160T

70

2.76

67

2.64

HM180T

135

5.31

133

5.24

131

5.16

HM180T

80

3.15

77

3.03

HM200T

145

5.71

143

5.63

141

5.55

155

6.1

153

6.02

151

5.94

175

6.89

172

6.77

170

6.69

HM200T

95

3.74

92

3.62

HM270T

HM270T

97

3.82

94

3.7

HM380T

HM380T

100

3.94

96

3.78

17

9813/5850-01

17

Maintenance Wear Limits and Tool for Lower Tool Bushing

Upper Dampener Wear Limits

Lower Dampener Wear Limits

P046730-50

Fig 13.

NEW

WEAR LIMIT (C)

mm

Inch

mm

Inch

HM012T

NA

NA

NA

NA

HM018T

20

0.79

18

0.71

20

0.79

18

0.71

P046730-49

Fig 12.

NEW

WEAR LIMIT (B)

mm

Inch

mm

Inch

HM026T

HM012T

NA

NA

NA

NA

HM033T

20

0.79

18

0.71

HM018T

54

2.13

52

2.05

HM054T

20

0.79

18

0.71

HM026T

78

3.07

75

2.95

HM080T

20

0.79

18

0.71

20

0.79

18

0.71

HM033T

78

3.07

75

2.95

HM090T

HM054T

78

3.07

75

2.95

HM120T

20

0.79

18

0.71

HM080T

100

3.94

96

3.78

HM160T

20

0.79

18

0.71

HM090T

100

3.94

96

3.78

HM180T

25

0.98

22

0.87

25

0.98

22

0.87

HM120T

110

4.33

106

4.17

HM200T

HM160T

110

4.33

106

4.17

HM270T

25

0.98

22

0.87

HM180T

125

4.92

121

4.76

HM380T

25

0.98

22

0.87

HM200T

125

4.92

121

4.76

HM270T

125

4.92

121

4.76

HM380T

125

4.92

121

4.76

18

9813/5850-01

18

Maintenance Wear Limits and Tool for Lower Tool Bushing

Upper Bush Wear Limits

Bottom Bush Wear Limits

P046730-52

Fig 15.

WEAR LIMIT (F) mm

Inch

HM012T

3

0.12

HM018T

3

0.12

HM026T

3

0.12

HM033T

3

0.12

HM049T

4

0.16

HM054T

4

0.16

HM080T

4

0.16

HM090T

4

0.16

HM120T

4

0.16

HM160T

5

0.2

HM180T

5

0.2

HM200T

6

0.24

HM270T

7

0.28

HM380T

7

0.28

P046730-51

Fig 14.

WEAR LIMIT (D)

WEAR LIMIT (E)

mm

Inch

mm

Inch

HM012T

5

0.2

NA

NA

HM018T

5

0.2

NA

NA

HM026T

5

0.2

NA

NA

HM033T

5

0.2

13

0.51

HM049T

6

0.24

13

0.51

HM054T

6

0.24

15

0.51

HM080T

6

0.24

9

0.35

HM090T

6

0.24

14

0.55

HM120T

6

0.24

9

0.35

HM160T

7

0.28

15

0.59

HM180T

7

0.28

8

0.31

HM200T

8

0.31

8

0.31

HM270T

9

0.35

13

0.51

HM380T

9

0.35

22

0.87

19

9813/5850-01

19

Maintenance Wear Limits and Tool for Lower Tool Bushing

Retainer Pin Wear Limits

P046730-53

Fig 16.

NEW

WEAR LIMIT (H)

mm

Inch

mm

Inch

HM012T

10

0.39

8

0.31

HM018T

10

0.39

8

0.31

HM026T

10

0.39

8

0.31

HM033T

15

0.59

13

0.51

HM049T

10

0.39

8

0.31

HM054T

10

0.39

8

0.31

HM080T

17.5

0.69

15.5

0.61

HM090T

17.5

0.69

15.5

0.61

HM120T

17.5

0.69

15.5

0.61

HM160T

17.5

0.69

15.5

0.61

HM180T

17.5

0.69

15.5

0.61

HM200T

17.5

0.69

15.5

0.61

HM270T

21.5

0.85

19.5

0.77

HM380T

27.5

1.08

25.5

1

20

9813/5850-01

20

Maintenance Wear Limits and Tool for Lower Tool Bushing

Housing Pad Wear Limits

P046730-54

Fig 17.

STANDARD VALUE

WEAR LIMIT

STANDARD VALUE

WEAR LIMIT

J mm

inch

mm

inch

mm

inch

mm

inch

106

4.17

109

4.29

106

4.17

109

4.29

HM018T

114

4.49

117

4.61

135

5.31

138

5.43

HM026T

132

5.2

135

5.31

142

5.59

145

5.71

HM033T

152

5.98

155

6.1

162

6.38

165

6.5

HM054T

177

6.97

180

7.09

177

6.97

180

7.09

HM080T

202

7.95

205

8.07

202

7.95

205

8.07

HM090T

222

8.74

225

8.86

222

8.74

225

8.86

HM120T

232

9.13

235

9.25

232

9.13

235

9.25

HM160T

252

9.92

255

10.04

252

9.92

255

10.04

HM180T

272

10.71

275

10.83

272

10.71

275

10.83

HM200T

282

11.1

285

11.22

282

11.1

285

11.22

HM270T

322

12.68

325

12.8

322

12.68

325

12.8

HM380T

342

13.46

345

13.58

342

13.46

345

13.58

HM012T

21

K

9813/5850-01

21

Maintenance Adjuster Valve to Control Impact Blows

Adjuster Valve to Control Impact Blows The blow of breaker is adjusted by oil flow of excavator, and reducing pressure valve in control valve at breaker line controls oil flow of excavator.

The blows of breaker can be adjusted with following procedure.

1

Release the nut of adjuster.

2

High speed (Low power) : turn adjuster to counterclockwise. (turn 2 cycle).

3

Low speed (High power) : turn adjuster to clockwise. (fully tighten).

4

Tighten the nut of adjuster after setting.

P047460-02

Fig 18.

22

9813/5850-01

22

Disassembly and Assembly Disassembly

Disassembly and Assembly Disassembly Accumulators Discharge Important: Wear protective gloves and safety glass.

Low Pressure Accumulators Use the JCB part 332/A2236 charging kit to discharge the accumulator.

1

Remove the gas charging valve plug from the head.

P046730-10

Fig 20.

3

Connect the gas charge adaptor.

P046730-11

Fig 19.

2

Make sure the pin in the gas charge adaptor is screwed in.

P046730-13

Fig 21.

4

Slowly turn the hand wheel on the gas charge adaptor to dischage the accumulator.

High Pressure Accumulators (HM026T - HM054T) Use the JCB part 332/A2236 charging kit to discharge the accumulator.

23

9813/5850-01

23

Disassembly and Assembly Disassembly 1

Remove the gas charging valve plug.

P046730-14

Fig 24.

P047460-89

2

Remove the cap over the gas charging valve.

Fig 22.

2

Make sure the pin in the gas charge adaptor is screwed in.

P046730-15

Fig 25.

3

Open the gas charging valve.

4

The accumulator will be heard to discharge.

5

Open the valve further to ensure the accumulator is completely discharged

Housing (Boxed) P046730-10

Fig 23.

3

Connect the gas charge adaptor.

4

Slowly turn the hand wheel on the gas charge adaptor to dischage the accumulator.

1

Remove the breaker tool. Refer to the Operator Manual for additional information.

2

Lower the breaker vertically on to the support.

High Pressure Accumulator (HM080T - HM380T) JCB part 332/A2236 gas charging kit is not required for discharging.

1

24

Remove the gas charging plug.

9813/5850-01

24

Disassembly and Assembly Disassembly 4

Remove the hoses.

5

Put the caps to the open ports and hoses.

6

Disconnect the grease hose from the automatic greaser (If installed).

P047460-01

Fig 26.

P047460-03

3

Fig 28.

Remove the hanger bolts.

7

Take out the upper dampener and the power cell holder.

P047460-02

Fig 27.

25

9813/5850-01

25

Disassembly and Assembly Disassembly

P047460-05

Fig 29.

8

Install an eyebolt to the head of the power cell.

P047460-06

Fig 30.

9

Lift the power cell out.

10

Clean the external faces of the power cell.

Housing (Side Plate)

26

1

Remove the breaker tool. Refer to the Operator Manual for additional information.

2

Put the breaker on its back on 3 suitable blocks of wood. Make sure the blocks should fit between the side plates and carry the weight of the power cell.

9813/5850-01

26

Disassembly and Assembly Disassembly

P047460-08

Fig 32.

7

Lift the side plates away.

P047460-07

Fig 31.

3

Remove the hoses.

4

Put the caps to the open ports and hoses.

5

Record the hose connections to the associated P and T on the breaker power cell (due to the variety of terminations on machine).

6

Remove the side bolts.

P047460-09

Fig 33.

Power Cell 1

27

9813/5850-01

Install the eyebolt in the top of the head.

27

Disassembly and Assembly Disassembly 2

Place the power cell on a vertical support.

P047460-11

Fig 35.

6

Lift the head.

P047460-10

Fig 34.

3

Loosen the tie rods evenly.

4

Remove the tie rods.

5

Remove the bottom tie rod nuts.

28

9813/5850-01

28

Disassembly and Assembly Disassembly

29

9813/5850-01

29

Disassembly and Assembly Disassembly P047460-12

Fig 36.

7

Remove the O-ring from the head.

P047460-13

Fig 37.

30

8

Install an eyebolt in the piston.

9

Lift the piston out of the cylinder.

9813/5850-01

30

Disassembly and Assembly Disassembly

P047460-15

Fig 39.

11

Remove the cylinder bush. Use a non metallic hammer or plastic drift to prevent damage to the piston.

12

Remove the cylinder bush seals. Record the orientation of the seals.

P047460-14

Fig 38.

10

31

Place the piston on the non metallic V blocks on a bench.

9813/5850-01

31

Disassembly and Assembly Disassembly

P047460-16

Fig 40.

13

Install two eye bolts to the each side of the cylinder.

14

Lift the cylinder from the tool housing.

P047460-17

Fig 41.

32

15

Remove the dowel (If installed).

16

Remove the O-ring.

9813/5850-01

32

Disassembly and Assembly Disassembly 19

If necessary, remove the plugs.

P047460-20

Fig 44.

P047460-18

20

Fig 42.

17

Place the cylinder on its back on the bench.

18

Remove the seals. Record their orientation.

Remove the valve cap. It can be pulled out with the use of an eyebolt.

P047460-21

Fig 45.

21

Remove the valve spool.

P047460-19

Fig 43.

33

9813/5850-01

33

Disassembly and Assembly Disassembly

P047460-22

Fig 46.

22

Use a suitable puller to remove the valve housing.

P047460-24

Fig 48.

2

Remove the cover.

3

Remove the diaphragm.

P047460-23

Fig 47.

High Pressure Accumulator Note: Make sure that the nitrogen gas is discharged from the accumulator.

1

34

Remove the accumulator bolts.

9813/5850-01

34

Disassembly and Assembly Disassembly

Tool Bushes 1

Remove stopper pins and the rubbber plug from the bottom bush and the upper bush.

P047460-25

Fig 49.

4

Remove the base from the cylinder.

P047460-27

Fig 51.

2

The bushes can be removed by any one of the following methods: a

Press

b Cutting c

Welding

The Cutting and Welding methods can be used with the breaker assembled to change the lower bush, to prevent damage to the piston, degas the low pressure accumulator and push the piston in.

Press 1

Place the tool housing on solid wood blocks.

2

Press the bushes out.

P047460-26

Fig 50.

35

9813/5850-01

35

Disassembly and Assembly Disassembly

A

B P047460-28

Fig 52.

A

Bottom Bush

B

Upper Bush

Cutting 1

Oxyacetylene can be used to cut the bush out, the bush has 3 flats on the external diameter. The cutting flame needs to cut through the bush but not penetrate the tool housing.

2

Make sure that this technique must only be attempted by a skilled operator.

Welding 1

36

The internal face of the bush is welded with a series of parallel welds, the initial heat shock and the following thermal contraction will free the bush.

9813/5850-01

36

Disassembly and Assembly Assembly

Assembly The breaker power cell is best cleaned with a steam cleaner, plug all open ports to prevent water and debris being forced into the internal areas.

2

Lubricate the seal and the mating face with oil.

3

Install the accumulator base to the cylinder, ensure the correct orientation. Smaller breaker accumulator bases are stepped.

4

Coat the accumulator diaphragm with grease around the edge.

All parts must be thoroughly cleaned.

- Small Parts: Use water to clean the parts.

- Large Parts: Use steam to clean the parts.

Blow out any galleries with compressed air to remove any residues, ensure all parts are dry before starting assembly.

Due to the weight and difficulty of retaining the assembly, tighten all the bolts and the nuts to a nominal figure and give the final tightening to the correct torque at the end of the assembly processes for the power cell.

The tool housing should be placed over a vertical bar/tube welded to a flat plate to support the breaker during the assembly process and of sufficient strength to resist torques applied whilst tightening the various bolts.

High Pressure Accumulator Note: The HM012T - HM018T do not have a high pressure accumulator.

1

Install the accumulator to the cylinder seal onto the base of the high pressure accumulator. Large breakers use the face seal with grease while the smaller breaker use an O-ring with a backup ring.

P047460-30

Fig 54.

5

Install the accumulator diaphragm.

P047460-31

Fig 55.

P047460-29

Fig 53.

6

37

9813/5850-01

Install the accumulator top.

37

Disassembly and Assembly Assembly

P047460-32

Fig 56.

7

Ensure correct orientation for the larger models, the cap over the charging valve faces away from the piston seals.

P047460-34

Fig 58.

Note: Two sizes of bolts are used.

9

Record the orientation of the washers.

10

Use loctite 277 on the threads.

11

Tighten to the figures specified or 10-20 Nm and then tighten on final assembly to correct torque.

P047460-33

Fig 57.

8

38

Identify the socket cap head bolts.

9813/5850-01

38

Disassembly and Assembly Assembly

Valve

4

Tilt the valve assembly end to end and make sure the spool is free.

A B

C

D P047460-35

Fig 59.

A

Valve Housing

B

Spool

C

Seals

D

Valve Cap

1

Coat the sliding surface of the spool with oil.

P047460-37

Fig 61.

5

Install the two O-rings.

6

Coat the valve cavity with oil in the cylinder.

P047460-36

Fig 60.

2

Ensure the spool is installed correctly in the valve housing.

3

Install the valve end cap.

39

9813/5850-01

39

Disassembly and Assembly Assembly

Piston Seal 1

Identify the piston seals, depending on machine model.

Note: The piston can be used as a gauge to identify the piston seals and the low pressure accumaulator seals.

2

Lubricate the seal with oil.

P047460-38

Fig 62.

7

Install the valve into the cylinder, this will require knocking into the housing. If necessary use a non metallic drift. Make sure the O-ring on the end is upper most.

P047460-40

Fig 64.

3

Submerge the seals in oil prior to fitting.

4

Install the buffer ring set. This is not applicable for HM 018T - HM 033T.

5

Install the U seal.

6

Install the dust seal.

P047460-39

Fig 63.

Note: The valve can be installed to the cylinder after the piston is installed in the vertical position, if this is done place a cloth over the piston to ensure contamination doesnot drop into the cylinder.

40

9813/5850-01

40

Disassembly and Assembly Assembly

A

C B

D P047460-41

Fig 65.

Tool Housing Assembly 1

With the tool housing placed upside down, press in the upper bush. Ensure the correct orientation, the inside diameter of the bush is smaller at one end.

2

Press in the lower bush. Ensure the correct orientation, the bush has a grove machined in for the retaining pin. Ensure this will align with the cross drilling in the tool housing when fully pressed home.

P047460-90

Fig 66.

A

Bottom Bush

B

Groove (Stopper Pin)

C

Groove

D

Upper Bush

3

41

9813/5850-01

The use of liquid nitrogen to shrink the bushes is an alternative to the use of a press, thus observe the warnings issued by the supplier and local regulations in the use of liquid nitrogen.

41

Disassembly and Assembly Assembly

Cylinder

3

Install the location dowel (smaller breakers do not have a dowel).

Note: The breaker should be assembled vertically on a vertical support.

1

Place the tool housing on the vertical support.

2

Install the O-ring.

P047460-43

Fig 68.

4

Install the two eye bolts on each side of the cylinder.

P047460-42

Fig 67.

42

9813/5850-01

42

Disassembly and Assembly Assembly

P047460-45

Fig 70.

8

Lift the piston using an eye bolt and position above the cylinder.

9

Coat the piston with a thin coat of oil.

P047460-44

Fig 69.

5

Lift the cylinder using the two eye bolts.

6

Lower onto the tool housing.

7

Coat the inside of the cylinder with oil.

P047460-46

Fig 71.

43

9813/5850-01

43

Disassembly and Assembly Assembly 10

Lower the piston into the cylinder.

11

Apply oil to the cylinder bush.

N2 GAS

A

E

B

C D

P047460-48

Fig 73.

P047460-47

Fig 72.

12

Identify the cylinder bush seals, the shape and number of seal varies with breaker model.

13

Soak the seals in oil.

14

Install the diaphram below.

15

Install the internal O-rings before the plastic part of the seal.

Note: The gas seal is not direction dependent, all the other seals are orientation dependent.

44

16

Install the external O-ring on the cylinder bush.

17

Install the O-ring in the top of the cylinder.

9813/5850-01

44

Disassembly and Assembly Assembly

P047460-49

Fig 74.

18

Install the cylinder bush, knock into the cylinder housing using a plastic drift.

P047460-50

Fig 75.

45

19

Coat the O-ring groove on the head with oil.

20

Soak the O-ring in oil.

21

Install the O-ring to the O-ring groove in the head.

9813/5850-01

45

Disassembly and Assembly Assembly

P047460-51

Fig 76.

22

Lift the head with an eye bolt and lower on to the cylinder. Make sure it fully contracts the cylinder.

P047460-52

Fig 77.

Note: The head may not balance correctly to lower squarely onto the cylinder, use a plastic drift or a suitable bolt in the front face eye bolt hole to square-up during lowering.

46

9813/5850-01

46

Disassembly and Assembly Assembly

P047460-53

P047460-55

Fig 78.

23

Fig 80.

Coat the threads on the tie rods with anti-seize compound (Loctite 76764).

25

Partially screw-in the tie rods. Make sure the flats are uppermost.

P047460-54

Fig 79.

P047460-56

24

Fig 81.

Install the bottom tie rod nuts. Note the Orientation.

26

47

9813/5850-01

Install the tie rod nuts. Note the orientation of the washers and the nuts.

47

Disassembly and Assembly Assembly

A

B

P047460-59

Fig 84.

P047460-57

Fig 82.

A

Short Boss on Nut

B

Lip on Washer Upper Most

Tightening Tie Rods Incrementally tighten to approximmately 150Nm for breaker model (HM012T to HM033T) and 500 Nm for other models.

27

Tighten to hand tight.

28

Ensure the tool housing, barrel and head are aligned, Larger breakers have location dowels to prevent misalignment.

Full torque can be applied by the following methods: - Angle Method - Torque Method

Angle Method (HM080T - 490 Nm) 1

Tighten the nuts in the sequence indicated to 882Nm or 1/6th of a turn if a torque wrench of sufficient capacity is not available.

2

Tighten the nuts in the sequence indicated to 2.2/6th (132 degrees) of a turn. For larger breakers additional intermediate steps are carried out either using torque or indexing of the nut before the final reading is reached.

P047460-58

Fig 83.

29

48

Prior to tightening the tie rod nuts, the top of the nut should be protrurde of the tie rod by 1-2mm.

9813/5850-01

48

Disassembly and Assembly Assembly

P047460-60

Fig 85.

P047460-61

Fig 86.

Note: To identify the angle turned, mark the nut in line with a mark on the top of the head with a marker pen.

The top units should be tightened, when increasing the torquestep by stepin each direction as the arrow mark on the below figure.

Torque Method (HM080T - 490 Nm) 1

Tighten the nuts in the sequence indicated to 882Nm.

2

Tighten the nuts in the sequence indicated to final torque of 1274 Nm. For larger breakers additional intermediate steps are carried using torque before the final reading is reached.

P047460-91

Fig 87.

49

9813/5850-01

49

50

Tightening Way In case of no power torque wrench, refer to the below table for tightening.

Model

Through Bolt (N.m)

Turning (N.m) 1 Step

2 Step

3 Step

4 Step

9813/5850-01

Turning

Setting

Turning (from 0 flat)

Setting

Turning (from previous step)

Setting

Turning (from previous step)(1)

HM012T 294

147

-

-

-

-

-

294

-

HM018T 441

196

-

-

-

-

-

441

-

HM026T 490

196

-

-

-

-

-

490

-

HM033T 490

196

-

-

-

-

-

490

-

HM049T 490

490

-

-

-

-

-

931

2.5/6

HM054T 931

490

-

-

-

-

-

931

2.5/6

HM080T 1274

490

-

882

1/6

-

-

1274

2.2/6

HM090T 1568

490

-

882

1/6

-

-

1568

2.2/6

HM120T 2352 (2646)

490

-

882

0.5/6

1470

1.5/6

2352

1/6 (1.4/6)

HM160T 2646 (3038)

490

-

882

0.5/6

1470

1.5/6

2646

1/6 (1.7/6)

HM180T 3234 (3724)

490

-

1470

1.5/6

2450

1.5/6

3234

0.5/6 (1/6)

HM200T 3234 (3724)

490

-

1470

1.5/6

2450

1.5/6

3234

0.5/6 (1/6)

HM270T 3822 (4410)

490

-

1470

1/6

2450

1.5/6

3822

1.2/6 (1.8/ 6)

HM380T 6076 (6958)

490

-

1960

1/6

3920

2/6

6076

1/6 (1.3/6)

50

Assembly

(1) Value in brackets () is applicable to Middle East, India and Mexico.Turning flat (nut degree) on 3rd step and 4th step should be turned from previous step.

Disassembly and Assembly

Setting

51

Tightening Procedure

2nd Step

1st Step

Turn up to Turning Number specified on the chart in former page for each model with ring spanner and hammer.

Tighten the top nuts up to 490 N.m with the torque wrench.

- Before turn it at 2nd step, make mark on an apex of top nut and back-head for ensure to tighten up to the specified turning number.

- Turn it with hammer every 1/6 number - turn top nut “A” 1/6 after then turn “B” and turn “C” and “D” in cross direction.

- Do not turn one unit full number at one time.

- Turn each nut every 1/6 turning number.

G BACK HEAD A

B

D

9813/5850-01

C

F

E

Quantity of Hydraulic Oil (cc)

HM012T

40

Marking Points

1

HM018T

50

HM026T

60

HM033T

80

HM049T

150

HM054T

180

HM080T

200

Through Bolt

F G

Completion of Tightening Fixings

51

Complete the final tightening of the accumulator bolts which were not torqued to the correct value during assembly.

2

Remove the charging valve.

Add the correct amount of oil as specified in the table below.

Assembly

Model

Top Nut

Fill the Low Pressure Accumulator with Oil

E

Disassembly and Assembly

P047460-92

Fig 88.

52

Model

Quantity of Hydraulic Oil (cc)

HM090T

220

HM120T

230

HM160T

300

HM180T

340

HM200T

400

HM270T

500

HM380T

700

3

Install the charging valve.

Checking the low pressure accumulator

!MDANGER Use only nitrogen gas to charge 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 the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere.

B-3-1-6_2

Note: Inspect the gas charging valve, if its damaged, suffering corrosion or fails to seal, install a new valve.

Gas Charging 9813/5850-01

Gas charging should be done with the breaker lying flat with no load on the tool/piston. This can be done on the bare power cell or when it’s assembled into the side plates or the breaker housing.

Important: If you do not understand any part of this document seek advice from your employer or JCB Distributor

P046730-08

Fig 89.

Check the low pressure accumulator shown is a boxed breaker version for side plate versions there is no access cover.

Note: Checking should be done with no load on the tool and the ports open, if mounted on a machine the hoses can remain connected if the return line is open to tank so not to trap pressure.

Keep clear of the tool at all times

Note: Wear gloves and safety glasses.

P046730-12

1

Fig 90.

Remove the acess cover.

2

Remove the charging plug.

Assembly

52

Disassembly and Assembly

Note: To avoid errors checking of accumlator pressure should be done after its allowed to cool, ensure the nitrogen cylinder is not exposed to extremes of temperature.

Disassembly and Assembly Assembly

P046730-11

Fig 91.

3

P046730-13

Fig 93.

Make sure the pin in the gas charge adaptor is screwed in.

5

Connect the nitrogen gas cylinder to the nitrogen regulator

Note: For some countries nitrogen cylinder adaptors will be required. .K Table 1. ( T 10) 6

Connect the link hose to the nitrogen regulator.

7

Connect the other end of the link hose to the charging adaptor.

Note: Make sure the bleed valve on the regulator assembly is closed.

8

Turn the hand wheel on the charging adaptor clockwise to open the charging port connection.

9

Read the pressure on the regulator gauge. a

10

If the accumulator is being charged from empty go to step 11.

Check gas pressure to the chart, conversion table for charging N2-gas pressure to back head.

If the pressure is ok close the charging valve by turning the hand wheel anti-clockwise. if the pressure is low.

11

Slowly Open the valve on the nitrogen bottle

P046730-10

12

Slowly increase the pressure on the nitrogen cylinder regulator until it reaches the upper limit of the correct pressure

Screw the charging adaptor into the charging port on the power cell head.

13

Close the nitrogen gas bottle valve.

14

Turn the hand wheel anti clockwise on the charging adaptor to close the charging port.

15

Recheck pressure in 5 to 15 minutes time.

Fig 92.

4

53

9813/5850-01

53

Disassembly and Assembly Assembly 16

Remove the charging adaptor.

17

Place a few drops of oil into the charging port, check for nitrogen leakage.

18

Replace the charging port cap and tighten to 1 - 3 Nm.

Charging the High Pressure Accumulator Note: This should be only done on commissioning the breaker or if loss of charge is suspected.

Note: The charging port of the larger breakers differ from the smaller breaker. Below is detailed the method of checking and charging the larger breaker. The smaller breaker have a charging port similar as the low pressure accumulator.

!MDANGER Use only nitrogen gas to charge 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 the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere.

B-3-1-6_2

Important: If you do not understand any part of this document seek advice from your employer or JCB Distributor Check the low pressure accumulator shown is a boxed breaker version for side plate versions there is no access cover.

Note: Checking should be done with no load on the tool and the ports open, if mounted on a machine the hoses can remain connected if the return line is open to tank so not to trap pressure.

Keep clear of the tool at all times Note: To avoid errors checking of accumlator pressure should be done after its allowed to cool, ensure the nitrogen cylinder is not exposed to extremes of temperature.

Note: Wear gloves an safety glasses.

1

54

9813/5850-01

Remove the access cover.

54

Disassembly and Assembly Assembly

P046730-14

Fig 96.

P046730-08

Fig 94.

3

Remove the cap over the filling valve.

P046730-12

Fig 95.

P046730-15

Fig 97.

2

Remove the charging plug.

4

55

9813/5850-01

Make sure the pin of the adaptor is screwed into the body of the charging adaptor.

55

Disassembly and Assembly Assembly 6

Connect the nitrogen gas cylinder to the nitrogen regulator, for some countries an adaptor may be required - see nitrogen cylinder adaptor chart.

7

Connect the link hose to the nitrogen regulator.

8

Connect the other end of the link hose to the charging adaptor.

P046730-21

Fig 100.

9 P046730-10

Fig 98.

5

Open the filling valve 1 - 1.5 turns with an allen key note there is no need to turn the hand wheel on the accumulator charging adaptor.

Screw the charging adaptor into the charging port on the high pressure accumulator top.

Make sure the area is clean.

P046730-20

Fig 99.

56

9813/5850-01

56

Disassembly and Assembly Assembly 19

Place a few drops of oil into the charging port, check for nitrogen leakage.

P046730-23

Fig 102.

P046730-22

Fig 101.

10

Replace the charging port plug and tighten to 1 - 3 Nm.

21

Replace the charging valve cap - tighten to 1 - 3 Nm.

Read the pressure on the regulator gauge. a

11

20

If the accumulator is being charged from empty go to step 12.

Check gas pressure to the specification section the JCB model numbers will have to be used.

If the pressure is low.

12

Slowly open the valve on the nitrogen bottle.

13

Slowly increase the pressure on the nitrogen cylinder regulator until it reaches 2-3 bar above the correct pressure.

14

Close the nitrogen gas bottle valve.

15

Close the charge port valve to close the charging port.

16

Recheck pressure in 5 to 15 minutes time.

17

Close the valve on the nitrogen cylinder.

18

Remove the charging adaptor.

57

9813/5850-01

57

Disassembly and Assembly Assembly

Conversion Table for Charging N2-Gas for the Low Pressure Accumulation (Power Cell Head) Gas pressure kg/cm

2

For Model Number: - HM012T - HM026T - HM054T - HM080T

Gas pressure kg/cm

2

- HM090T

18 17 16 15 14 13 12 11 10 9 8 7 6

ha

as c

ge

n e ra

Th

of

rg

ha

sc

de

em

m com

f re

eo

e

Th

-20

g ran

a dg

re ep

0 20 40 60 Ambient temperature C ( F)

80

o

o

e

P046730-32

Fig 104.

For Model Number:

m

me

om rec

g ded

re

ssu

sur

res

p rge

22 21 20 19 18 17 16 15 14 13 12 11 10

- HM018T - HM120T - HM160T - HM180T - HM200T

-20

0 20 40 60 Ambient temperature C ( F) o

- HM270T

80

- HM380T

o

P046730-31

Fig 103.

For Model Number:

Gas pressure kg/cm

2

- HM033T

22 21 20 19 18 17 16 15 14 13 12 11 10

re

ssu

co

f re

The

-20

o nge

ed

md

e mm

gas

re ep

rg

cha

ra

0 20 40 60 Ambient temperature C ( F) o

o

80 P046730-33

Fig 105.

58

9813/5850-01

58

Disassembly and Assembly Final Assembly

Final Assembly Installment of Power Cell into Housing 1

Place the housing over a vertical bar or tube welded to a plate.

2

Inspect all the internal wear pads and buffers for wear. Refer the table for wear limits and replace if necessary.

3

Install an eyebolt to the top of the head.

4

Lift the power cell and lower into the breaker housing.

Be careful not to dislodge the side wear pads.

5

Remove the eyebolt.

6

Install the upper buffer.

7

Install the power cell holder and its associated wear pad.

8

Use a suitable lifting strap to lift the hanger bracket.

Torque Nm

M36

2400

HM380T

M36

2400

10

For models HM080T and above, connect the grease hose from the power cell to the auto greaser.

11

Remove the caps from the breakers power cell ports.

12

Feed the hoses through the front panel and connect the hoses. All breakers use the same hose for feed and return but the adaptor or QRC fitted on the hose makes it the feed or return hose. The ports on the power cell are marked with P and T.

13

Tighten to the torques as specified in the Hose Torque Settings.

Installment of Power Cell into Side Plates Place the power cell on the three blocks. Make sure the blocks should fit between the side plates and carry the weight of the power cell.

b HM080T to HM380T Model : Inspect heli-coil inserts, replace if necessary and attach with socket cap bolts and nordlock washers.

2

Install the side plates.

3

Install the side bolts.

Tighten to the correct torque value. Refer to Table 2.

4

Tighten the bolts to a torque value of 10Nm.

5

Check the following:

HM012T to HM054T Model : Attach with nuts, bolts and nordlock washers.

Model

Table 2.

Bolt Size

Torque Nm

HM012T

M16

200

HM018T

M18

250

HM026T

M18

250

HM033T

M18

250

HM054T

M18

250

HM080T

M24

690

HM090T

M24

690

HM120T

M24

690

HM160T

M24

690

HM180T

M24

690

HM200T

M24

690

59

Bolt Size

HM270T

1

a

9

Model

a

Alignment of the pivot bores

b Installment of dipper and tipping link pivot pins 6

Tighten to the specified torque value.

7

Make sure that the pivot bores are aligned.

8

Install the breaker tool. Refer to the Operator Manual for more details.

9

Install the hoses. Make sure that the correct QRC on the hose connects to the correct port.

9813/5850-01

59

Disassembly and Assembly Final Assembly

Grease Charging on Models with Automatic Greasing System After a complete strip down, the grease gallery in the power-cell to the tool housing may be empty of grease.

Manually grease the breaker.

Grease Nipple for manual greasing of the Breaker

Lock Nut Adjuster Direction of rotation of the Adjuster

Fully Closed (Min. Output) Fully Open (Max. Output)

Grease Nipple for grease refilling of the cartridge P033480-30

Fig 106.

Continue manually greasing until grease starts to flow into the upper bush area.

60

9813/5850-01

60

Service Repair of Parts When correcting faults on sliding surfaces, finish surfaces as smooth as possible. Use an oilstone, emery paper and flex hone to remove surface defects. Overworking/ removal of too much material may cause malfunction or excessive internal leakage an overheating.

Polishing or sanding of parts must only be done at 90 degrees to the direction of moment.

Control Valve 1

Inspect the valve for signs of seizure or scuffing.

Scuffing marks due to seizure or contamination can be polished away by fine oilstone or sand paper (#1000~1200).

2

The corresponding marks on the valve bush or valve cap should be removed in the same way.

3

If surface damage/scratch is excessive, replace with a new control valve assembly.

Tool for Correction Tool Name

Grain Type Rough Finish

Finish

Oilstone

Rough and medium grain

Finish grain

Emery Paper

#100, #160, #240

#400, #600

Operating Method Polish perpendicular to a sliding direction

Inspection Seals 1

Check for scratches, deformation.

brittleness,

cracking

or

2

Do not remove to check. Even a small scratch can lead to leakage.

3

Whilst the breaker is stripped down it is wise to change all the seals.

P047460-63

Fig 105.

Piston 1

Deformation of the lower end of piston must be checked. Small areas of peeling can be removed. If the corner of the piston is chipped, replace the piston.

2

Check piston for seizure marks and scuffing. Remove by polishing with an oilstone or emery paper (#1000~1200). Corresponding marks on the mating part should also be treated in the same way.

P047460-62

Fig 104.

59

9813/5850-01

59

Service Repair of Parts

P047460-65

Fig 107.

P047460-64

Fig 106.

Caution on using the buffer grinder Table 3.

Kind of Fault

Condition

Remedy

Striped scratches caused by sliding motion

Remove burrs on the surface by polishing in the circumferential direction

Vertical scratch

Scratch in labyrinth grooves

Correct scratches at an early stage as scratches in Removes burrs sticking above labyrinth grooves this area may develop into a fatal failure of the and finish edges and finish edges and remedy vertical scratches cylinder

60

9813/5850-01

60

Service Repair of Parts Kind of Fault

Condition

Remedy

Corner of sliding section is chipped

Taking piston on polishing machine. Remove burrs on surface by polishing in circumferential direction for max. 0.05 mm less of normal diameter. If scratches and/or rust pit still remain replace piston by new one

Reparation vertical scratch and/or rust pit

Cylinder Bush and Cylinder 1

When using the grindstone, use in a circular action to maintain circularity.

2

Wash the parts thoroughly to remove any traces of abrasive material.

P047460-66

Fig 108.

61

9813/5850-01

61

Service Repair of Parts Caution on using the buffer grinder Table 4.

Kind of Fault

Condition

Remedy

A stripped fault running in the sliding direction of the blow piston

If burrs stick out above labyrinth grooves, remove burrs and correct vertical faults with oil stone and/ or emery paper

A localized fault that is wider than the vertical scratch and is caused by sliding motion

Finish galling with an oil stone till no step exists on the outer surface and then finish with fine emery paper

Vertical scratch

Galling

62

9813/5850-01

62

Service Repair of Parts Kind of Fault

Condition

Remedy

Corner of sliding section is chipped

Finish an edge produced by chipping smoothly with an oilstone

Chipping

63

9813/5850-01

63

Service Automatic Lubrication

Automatic Lubrication Installation 1

It must be installed parallel with the tool of the breaker.

A

B

C

P047460-67

Fig 109.

64

A

Grease Hose

B

Breaker

C

Tool

9813/5850-01

64

Service Automatic Lubrication Note: The pump body should be tightened strictly on the breaker. Loosened bolt may cause serious damage or malfunction.

Note: The grease cartridge should be tightened on the pump body. Loosened screw may cause serious damage or malfunction.

Refilling 1

Refill with extreme hammer grease through the filling grease nipple, be carefull not to overfill the reservoir.

A P047460-69

Fig 111.

Adjuster 1

The rate of grease lubrication is controlled by the adjuster screw on the side of the housing.

Grease Nipple for manual greasing of the Breaker

P047460-68

Fig 110.

A

Power pump Lock Nut Adjuster Direction of rotation of the Adjuster

Fully Closed (Min. Output) Fully Open (Max. Output)

Grease Nipple for grease refilling of the cartridge P033480-30

Fig 112.

2

65

9813/5850-01

The rate of lubrication should give a grease mark equal to the diameter of the tool.

65

Service Automatic Lubrication

P029691

Fig 113.

Operation 1

If the correct operation of the greaser can be checked by running the breaker for 3 minutes with the grease hose removed. K Fig 114. ( T 66)

P047460-70

Fig 114.

66

9813/5850-01

66

Service Automatic Lubrication

Installment of Tool 1

A

B

N

Q

After a strip down and full service, ensure all contact faces of the tool, tool retainer pins, and bushes are coated with extreme hammer grease prior to assembly. Refer to the Operator Manual for more details.

P M L C

K

D

J E F G H

P047460-71

Fig 115.

Item Number

Name

A

Catridge

B

O-ring

C

Spring

D

Body

E

Plug

F

Bolt

G

Grease Nipple

H

Grease Nipple

J

Ball

K

Ball

L

Spring

M

Cover

N

Adjuster

P

Locknut

Q

Output Nipple

67

9813/5850-01

67

Service Fault Finding

Fault Finding Problem

Cause

Solution

Remarks

The Breaker does not start or Run

Connected back wards

Check connections: P = pump/pressure line T = tank/return line

Auxilliary ball valve closed

Check connections

Use retainer to open lock

Switch spool siezed

Contact your JCB dealer

Inspect

No load on tool

Blank fire protection needs load on tool Non genuine tool

Too low pressure setting on carrier Contact your JCB dealer machine

The Breaker runs slow

Too much pressure in low pressure accumulator

Piston can not lift

High Back pressure

Piston can not lift

Oil leaked into low pressure accumulator

Piston can not lift

Piston failure

Contact your JCB dealer

Too much pressure in low pressure accumulator

Forcing oil over relief valve

Low relef valve setting

Low flow

High pressure accumulator high on gas pressure

Forcing oil over relief valve

Incorrect restrictor

Too small

Insufficient oil flow

Correct pump mode

Inspect

Check return line and renew filter

Combined with overheating

Forcing oil over relief valve

Pilot pressure valve pressure setting

68

Ball valve partially closed

Check

Oil leaked into low pressure accumulator

Check

Correct setting of adjuster valve

Check

Check stroke valve

Adjust

9813/5850-01

Use retainer to lock open

68

Service Fault Finding Problem

Cause

Solution

Remarks

Check pressure

If problem persists inspect accumualtor also hose vibration

Check for debris

Strip breaker and clean

Loss of precharge in LP accumulator

Check pressure

If problem persists inspect piston and seal

Low flow

Carry out flow and pressure check on machine

Worn machine or faulty ARV/MRV

Machine in wrong setting

See opertaor manual

Check

Use retainer to lock open

Loss of breaking power Loss of precharge in HP accumulator

Ball valve partially closed

May lead to over heating Over heating

Oil degraded

Check cooling capacity

Drop in oil viscosity

Check oil grade

Incorrect oil viscosity

Worn piston and bore

High internal leakage

Ball valve partially closed

Check and lock open if necessary

Loss of viscosity / increased leakage

Take oil sample for analysis

Over greasing allowing grease past piston seal Loss of precharge in low pressure Check and adjust if accumulator neccesary

Hose vibration

69

Loss of precharge in HP accumulator

Always check at the correct temperature and recheck 5 minutes later

Check / Adjust and re-check If problem persists 5 minutes later inspect HP accumualtor

9813/5850-01

69

Service Fault Finding Problem

Cause

Solution

Remarks

Lack of lubrication

Increase lubrication

Adjust CONTI LUBE

Grease mark should equal diameter of tool

Cartridge empty

Replace / Refill

Cartridge damaged

Inspect

Lubrication system sucking in air

Cartrigde end not open

Inspect

Check

Over Heated

Check machine set up and cooling

Grease melts and runs out

Check operator technique

Observe 15s rule

Worn tool or bush

Lubricant escapes

Wear accelerated

Debris enteres at a greater rate

Wear accelerated

Inspect piston and seal

Damaged piston seal due to debris

Check tool and bush clearance

Damaged piston due to tool being struck at an angle

Run in hammer mode

Lack of lubrication bush wear causing piston failure leading to seal failure

Seal missing Cartrigde not screwed IN

Oil leaking from tool bush

Piston seal leaking

Trapped pressure Over Heated

Leaking from housing

70

Seals worn / brittle

Check condition of carrier machine and set up

Check operator technique

Observe 15s rule

Lack of lubrication

Debris in chamber

Accelerated wear of piston seal

Face operation

Debris in chamber

Accelerated wear of piston seal

Low temperature operation

Seal stiff

Pre warm up

Accelerated wear due to contamination

Oil by passing filter

Seal installed incorrectly

Most possible cause after a service

Hose connections

Check hose connections

Life shortened by in correct setup

General seal failure

Check

Re commission / check carrier machine

9813/5850-01

70

Service Fault Finding Problem

Cause

Solution

Remarks

Tool wear

Lack of lubrication

Renew bush and tool

Check lubrication rate after commissioning

No initial lubrication of tool on assembly

Bush wear

Incorrect operator technique

Observe 15 second rule

None perpendicular tool to material

Ensure tool is square to face Tool bush oval

Worn tool bush

Replace

Check lubrication rate after commissioning

Worn retainer pins slots

Use of moil instead of chisel

Twisting of tool, replace retainer pins if necessary

Tip break up / mushroomed

Over heated

Observe 15s Rule / Operator technique

Retention pin wear

Use of chisel in rebar reinforced concrete

Torsion loading on tool

Lack of lubrication

Renew bush and tool

Check lubrication rate after commissioning

No initial lubrication of tool on assembly

Tool retention pin wear

Piston / Tool break up

71

Incorrect operator technique

Observe 15 second rule

None perpendicular tool to material

Make sure tool is square to face

Tool bush oval

Worn tool

Replace

Check lubrication rate after commissioning

Use of chisel in rebar reinforced concrete

Torsion loading on tool

Use a moil

Lack of lubrication

Check for visible grease mark on tool

Pins not rotated to extend life

Rotate pins

Incorrect commissioning

Grease pins on initial assembly

Angular piston contact with tool

Renew piston, tool and tool bush

Full strip down and inspection of piston and barrel

Severe wear due to lack of lubrication

See all faults associated with lack of lubrication

Over speeding

To high oil flow

Operation under water

Pressure shocks

9813/5850-01

71

Service Fault Finding Problem

Cause

Solution

Remarks

Errosion of internal parts

Wear due to contamination

Wear leading to change of operation or overheating

Renew filter, check oil

Pitting due to air in hydraulics

Wear leading to change of operation or overheating

Renew filter, check oil, oil may smell burnt

Levering rock

Break smaller pieces and observe 15s rule

Do not lever with tool

Low temperature operation

Store in doors

Warm up slowly

Carrier machine has insufficient cooling

Seek advice

Oil viscosity / condition out of specification

Excessive internal leakage

Worn breaker

Excessive internal leakage

Machines ARV/ MRV incorrect

Oil passing over relief valve creating heat

Operating at too high flow rate

Re-commission installation

Snapped tool

Over heating

Machine in wrong setting

72

High pressure accumulator high on gas pressure

Forcing oil over releif valve

Too much pressure in low pressure accumulator

Forcing oil over releif valve

9813/5850-01

Carry out loop test

See opertaor manual

Combined with runs slow

72

Service Disposal of Consumable

Disposal of Consumable End of Life Disposal Dispose of the hydraulic breaker and the hydraulic oil in accordance with the applicable statutory provisions on environmental protection in your local area.

Important: The hydraulic breaker is pressurised with nitrogen gas. While disposing the breaker, the high and low pressure Accumulators must be first depressurised by qualified personnel.

Hydraulic oil has to be drained from the hydraulic lines and disposed in accordance with the applicable environmental regulations.

73

9813/5850-01

73

Service Disposal of Consumable

Page left intentionally blank

74

9813/5850-01

74

77

Specification Machine Specification JCB MODEL Operating Weight Overall Length

Tool Diameter

HM012T HM018T HM026T HM033T HM049T HM054T HM080T HM090T HM120T HM160T HM180T HM200T HM270T HM380T

9813/5850-01

kg

120

187

260

330

495

545

800

900

1,150

1,580

1,800

2,000

2,700

3,800

lb

265

412

573

728

1,091

1,202

1,764

1,984

2,535

3,483

3,968

4,409

5,952

8,378

mm

1,135

1,450

1,513

1,639

1,894

2,062

2,125

2,234

2,442

2,589

2,775

2,906

3,085

3,580

inc h

44.69

57.09

59.57

64.53

74.6

81.18

83.66

87.95

96.14

101.93

109.25

114.41

121.46

140.94

mm

45

57

70

75

80

90

95

105

115

135

135

145

155

175

inc h

1.77

2.24

2.76

2.95

3.15

3.54

3.74

4.13

4.53

5.31

5.31

5.71

6.1

6.89

-

-

-

-

-

-

-

210

210

210

210

210

230

210

-

-

-

-

-

-

-

3,000

3,000

3,000

3,000

3,000

3,300

3,000

Carrier Relief Valve Setting

90~120 110~165 120~16 5

140~17 0

140~17 0

140~18 0

140~19 0

140~19 0

160~19 0

160~19 0

160~19 0

160~19 0

150~19 0

psi

1280~ 1700

1280~ 1700

1700~ 2350

1990~ 2420

1990~ 2420

1990~ 2560

1,990~ 2700

1,990~ 2700

2,275~ 2700

2,275~ 2700

2,275~ 1700

2,275~ 2700

2,130~ 2700

90~120

90~120 110~165 120~16 5

140~17 0

140~17 0

160~17 0

160~17 0

160~17 0

160~17 0

160~17 0

160~17 0

160~17 0

150~17 0

12~25

23~70

29~65

34~76

38~85

42~94

63~102

68~119

85~127 115~155 119~161 127~17 8

170~23 8

204~27 2

gal/ 3.2~6.6 min

6.1~18.

5

7.7~17.

2

9~20.1

10.0~22 .5

11.1~ 24.8

16.4~27 18~31.5

550~ 1000

600~ 1500

380~ 1000

380~90 0

400~80 0

350~70 0

350~60 0

-

-

-

-

600~110 0

490~ 1000

600~90 0

10~14

14~16

10~14

16~18

10~14

10~14

10~14

10~14

14~16

14~16

14~16

14~16

14~16

14~16

psi 142-199 199-228 142-199 228~25 6

142~19 9

142~19 9

142~19 9

142~19 9

199~22 8

199~22 8

199~22 8

199~22 8

199~22 8

199~22 8

JCB Recommended Data Plate Pressure Oil Flow

Blow Rate Low

l/m

bp m

Blow Rate High Low Pressure Accumulator

bar

1565~ 2350

22.5~ 33.5

30.5~41

31.5~ 42.5

33.5~47

45~63

54~72

350~55 0

320~55 0

320~48 0

340~45 0

270~40 0

230~40 0

230~33 0

600~90 0

400~70 0

400~60 0

420~55 0

400~70 0

270~47 0

270~50 0

77

Specification

90~120

Machine Specification

Operating Pressure bar

78

JCB MODEL

HM012T HM018T HM026T HM033T HM049T HM054T HM080T HM090T HM120T HM160T HM180T HM200T HM270T HM380T

High Pressure Accumulator

bar

-

-

-

psi

-

-

-

55~60

55~60

55~60

55~60

55~60

55~60

55~60

55~60

569~711 569~711 569~711 782~85 3

40~50

40~50

40~50

782~85 3

782~85 3

782~85 3

782~85 3

782~85 3

782~85 3

782~85 3

Carrier Weight

ton

0.8~2.5

1.5~4.0

3~6.5

4.5~8

4.5~8

6~10

10~15

10~15

12~18

18~24

20~26

24~30

28~42

40~60

lbs

1760~ 5500

3300~ 8800

6600~ 14300

9900~ 17600

9900~ 17600

13200~ 22000

17600~ 27500

22,000~ 26,500~ 39,700~ 44,100~ 52,900~ 61,700~ 88,200~ 33,000 40,000 53,000 57,500 66,000 92,500 132,500

9813/5850-01

Specification

Machine Specification

78

Specification Torque Settings

Torque Settings BSP Hose Connection Breaker

BSP Thread size

Dash size

Recommended torque (Nm)

Max. Remedial Torque (Nm)

HM012T

1/2

-8

50-55

72

HM018T

1/2

-8

50-55

72

HM026T

1/2

-8

50-55

72

HM033T

3/4

-12

85-94

126

HM054T

3/4

-12

85-94

126

HM080T

3/4

-12

85-94

126

HM090T

3/4

-12

85-94

126

HM120T

1

-16

115-127

153

HM160T

1

-16

115-127

153

HM180T

1

-16

115-127

153

HM200T

1 1/4

-20

190-209

234

Code 62 SAE Flange Coupling

79

Breaker

Nominal SAE flange size (inch)

SAE dash size

Metric coarse

Recommended fastener torque (Nm)

HM270T

1 1/4

-20

M12

56-68

HM380T

1 1/4

-20

M12

56-68

9813/5850-01

79

Specification Torque Settings

Page left intentionally blank

80

9813/5850-01

80

Part Numbers Breaker Models MODEL

HM012T

MACHINE FITMENT

PICKUP

PART NUMBER

COMPRISES OF Breaker

Installation Kit

Micro

25mm x 90mm CRS

980/A6283

Universal

Flange 242 x 242mm

980/A6282

802 , 8025, 8030, 8035, 804 (130crs only) 35mm x 130mm CRS

980/B0260

8020

25mm x 90mm CRS

980/B0261

1CX

35mm x 130mm CRS

980/B0263

Universal

Flange 300 x 260mm

980/B0262

803, 8035 804

35mm x 130mm CRS

980/B0254

47Z,51C,55Z&56C

45mm x 245mm

980/B0259

2CX 3CX Compact

1 1/4" x 231mm CRS 980/B0256

Universal

Flange 420 x 360mm

980/B0255

8052 - 8086 65R, 67C, 85Z 86C 85Z 86C 1 3/4" x 343mm CRS 90Z 100C

980/B0251

48/55ZTS/51RTS/57CTS

45mm x 245mm

980/B0258

3CX, 4CX, 5CX

1 3/4" x 343mm CRS

980/B0250

Universal

Flange 480 x 320mm

980/B0253

8080 - 8086 85Z 86C 85Z 86C 90Z 100C 1 3/4" x 343mm CRS

980/B0264

4CX, 5CX

1 3/4" x 343mm CRS

980/B0265

Universal

Flange 480 x 320mm

980/B0265

HM080T

JS130 - 145 Including JZ Varients

65mm x 385mm CRS

980/B0200 980/B0222

Universal

Flange 580 x 420mm

980/B0222

HM090T

JS130 - 145 Including JZ Varients

65mm x 385mm CRS

980/B0201 980/B0223

980/B0235

JS160 - 190

80mm x 435mm CRS

980/B0202 980/B0223

980/B0236

JS 200W

80mm x 450mm CRS

980/B0203 980/B0223

980/B0237

HM018T

HM026T

HM033T

HM054T

HM120T

HM160T

81

980/B0235

Universal

Flange 580 x 420mm

980/B0223

JS 160 - 190

80mm x 435mm CRS

980/B0204 980/B0206

980/B0238

JS200W

80mm x 450mm CRS

980/B0205 980/B0206

980/B0239

Universal

Flange 580 x 420mm

980/B0206

JS 200 - 220 Including JZ Varients

80mm x 450mm CRS

980/B0207 980/B0209

980/B0239

JS 240/260

90mm x 490mm CRS

980/B0208 980/B0209

980/B0240

Universal

Flange 580 x 420mm

980/B0209

9813/5850-01

81

Part Numbers Breaker Models MODEL

HM180T

HM200T

HM270T

HM380T

82

MACHINE FITMENT

PICKUP

PART NUMBER

COMPRISES OF Breaker

Installation Kit

JS200 - 220

80mm x 450mm CRS

980/B0210 980/B0212

980/B0241

JS240 - 260

90mm x 490mm CRS

980/B0211 980/B0212

980/B0242

Universal

Flange 640 x 480mm

980/B0212

JS240 -240

90mm x 490mm CRS

980/B0213 980/B0215

980/B0243

JS290

90mm x 565mm CRS

980/B0214 980/B0215

980/B0244

Universal

Flange 640 x 480mm

980/B0215

JS290 - 370

90mm x 565mm CRS

980/B0216 980/B0218

980/B0245

JS450 - 500

100mm x 570mm CRS 980/B0217 980/B0218

980/B0246

Universal

Flange 715 x 515mm

JS 460

100mm x 570mm CRS 980/B0221 980/B0224

Universal

Flange 810 x 650mm

9813/5850-01

980/B0218 980/B0247

980/B0224

82

Part Numbers Breaker Models

Page left intentionally blank

83

9813/5850-01

83