jcb 929/92400 User manual

JCB HAND HELD
HYDRAULIC
EQUIPMENT
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: [phone]

INTRODUCTION Section A
MAINTENANCE (HM 22, 25, 29) Section B
MAINTENANCE (OTHERS) Section C
SPECIFICATION Section D
HYDRAULIC POWERPACKS 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.

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:
1Standard handle breakers
2Vibro-damped handle breakers
3‘D’ handle picks
4‘T’ handle picks
5HM 22
6HM 25
7HM 29
8HM 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

Only use the following torque settings when no setting is specified in the manual.
CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced
with bolts of a lesser tensile specification.
TABLE OF IMPORTANT TIGHTENING TORQUES
Tightening Points Tightening Torques Capscrew
Nm kgf m lbf ft Size
Top cover to head capscrews (Standard, 20 kg & 23 kg) 135 13.8 100 M12
Top cover to head capscrews (Standard, 26 kg) 215 21.9 158 M14
Handle bracket to head capscrews (Vibro, 22 kg & 25 kg) 135 13.8 100 M12
Handle bracket to head capscrews (HM22 & HM25) 135 13.8 100 M12
Handle bracket to head capscrews (Vibro, 28 kg) 215 21.9 158 M14
Handle bracket to head capscrews (HM29) 215 21.9 158 M14
Handle to top cover capscrews (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 (HM29) 215 21.9 158 M14
Head assy to barrel/nose assy (Standard 20 kg & Vibro 22 kg) 135 13.8 100 M12
Head assy to barrel/nose assy (HM22) 135 13.8 100 M12
Head assy to barrel/nose assy (Standard 26 kg & Vibro 28 kg) 215 21.9 158 M14
Head assy to barrel/nose assy (HM29) 215 21.9 158 M14
Accumulator top to head capscrews (‘D’ & ‘T’) 80 8.1 59 M10
Barrel to head capscrews (‘D’ & ‘T’) 135 13.8 100 M12
Note:Check breaker specification to match breaker weight with the model number of your breaker.(see Section D)
A2 INTRODUCTION
9803/1250
A2
Issue 2
TORQUE SETTINGS

A3 INTRODUCTION
9803/1250
A3
Issue 1
SAFETY DECALS
Decals on the breaker warn you of particular
hazards.Read, and make sure you understand the
safety message before you work with the breaker.
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment
points on the breaker are as shown. Each decal has a
part number printed on it. Use this number to order a
new decal from your JCB Distributor, specifying the
language required.
In addition to the decals shown in the illustration
below, possibly three (3) other decals may be fitted.
These are year/model number, tool size and model
type. They have been omitted from the illustration for
clarity.
The model shown is an HM 25 but all other models are
similar.
55

BMAINTENANCE
9803/1250
B
Issue 1
CONTENTS
Lubricants - Health and Safety B1
Hygiene
Storage
Handling
First aid - Oil
Fires
Waste disposal
Service Schedules B2
Daily
Monthly
Breaker 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.

B1 MAINTENANCE
9803/1250
B1
Issue 1
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand this
information and the publications referred to. Make sure
that all of your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purpose.
However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take
special care when handling used oils which may be
diluted with fuel contamination.
Whenever you are handling oil products you should
maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued by
your Local Health Authority, plus the following.
Storage
Always keep lubricants out of reach of children. Never
store lubricants in open or unlabelled containers.
Handling
New Oil
There are no special precautions needed for the
handling or use of new oil, beside the normal care and
hygiene practices.
Used Oil
Used oils contain harmful contaminants. Here are pre
cautions to protect your health when handling used oil.
1Avoid prolonged, excessive or repeated skin
contact with used oil.
2Apply a barrier cream to the skin before handling
used oil.
3Note the following removing oil from the skin:
aWash your hands thoroughly with soap and
water.
bUsing a nail brush will help.
cUse special hand cleansers to help clean dirty
hands.
dNever use petrol, diesel fuel or paraffin for
washing.
eAvoid skin contact with oil soaked clothing.
fDo not keep oily rags in pockets.
gWash dirty clothing before reuse.
hThrow away oil soaked shoes.
First Aid-Oil
Swallowing
If oil is swallowed do not induce vomiting. Get medical
advice.
Eyes
In the case of eye contact, flush with water for 15
minutes. If irritation persists get medical attention.
Skin
In the case of excessive skin contact, wash with soap
and water.
Spillage
Absorb on sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Fires
Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self -contained breathing
apparatus.
Waste Disposal
All waste products should be disposed of in
accordance with the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour
used oil into sewers, drains or on the ground.

B2 MAINTENANCE
9803/1250
B2
Issue 1
SERVICE SCHEDULES
To make sure your breaker keeps working to maximum
efficiency, it is essential that it is properly and regularly
maintained in accordance with the service schedules
included in this manual.
Badly maintained equipment can be a danger to the
operator and the people working around him. Make
sure that the regular maintenance and lubrication jobs
listed in the service schedules are done to keep the
equipment in a safe and efficient working condition.
Any defects found during the regular routine
maintenance checks must be rectified before the
equipment is used.
Daily
Clean
1The breaker, its steels and its hoses.
Check (Breaker disconnected)
2All hydraulic connections.
3For damage to the breaker, its steels and its
hoses.
Monthly
Check (Breaker disconnected)
1Torque tightness of all fasteners.
2The hexagon bush in the nose casting for wear or
damage.
3The cutting steel shanks for excessive wear.
Lubricate
1Vibro-damped handle types only. Spray the
trigger and all contacting parts with suitable
lubricant.
Every 600 Operating Hours or Yearly
(which ever occurs first.)
1Overhaul the breaker.
!!WARNING
Maintenance work must only be done by
competent personnel.
A-3-1-1
!!CAUTION
Only use lubricants and hydraulic fluids
recommended by JCB Attachments.

B3 MAINTENANCE
9803/1250
B3
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29
6Unscrew and remove check valve Eensuring that
the breaker is positioned as shown above so as
to avoid losing the check valve ball F.
5Push the piston Cand piston feeder Dout of the
barrel. Remove 3 ‘O’ rings from the barrel.
CC
DD
FFEE
4Prepare for oil spillage and remove the two upper
barrel fixing capscrews. Remove the barrel A.
AA
3Before commencing dismantling, clean
externally. Remove the hoses. Remove the two
lower barrel fixing capscrews. Separate the
barrel A from the nose B.
BB
AA
1Using a press, remove roll pins Qfrom the
nose.This releases latch R, latch plunger Sand
the plunger spring.
SS
OO
RR
2Unless signs of damage or wear are evident it is
not necessary to remove the tool bush. Removal
will be dealt with in the following ‘Breaker
Inspection’.

B4 MAINTENANCE
9803/1250
B4
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)
7Remove the seals from the lower section of the
barrel casting. A slide hammer will be necessary
to remove the seal housing.
8Remove the housing cap Gand the spool Hfrom
the head J.
12 Remove vibration dampening springs.
11 Unscrew the handle pivot pin Znearest the
trigger pin. Withdraw handles assemblies from
the handles control bracket.
ZZ
ZZ
GG
JJ
HH
10 Remove screws (4 off each cover) from covers N
(2 off), this will expose the handle mechanism.
NN
9Remove the plug K, seal washer L, spring and
trigger spool Mfrom the head J. Examine seals
on the head Jand housing cap G.
JJ
MM
LL
KKGG

B5 MAINTENANCE
9803/1250
B5
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)
13 Remove the cover screw Tto expose the
charging screw.
14 Loosen the charging screw U slowly
approximately 3 or 4 turns, listening for all the
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 Vfrom 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 Xfrom the head.
XX
17 Remove the trigger pin Wand the ‘O’ ring seal Y
from the head.
WW
YY
PP
PP
VV
UU
TT
TT

B6 MAINTENANCE
9803/1250
B6
Issue 1
BREAKER INSPECTION - HM 22, 25, 29
1Examine the piston C, piston feeder Dand barrel
A for signs of damage. Small scratches can be
carefully removed with fine emery cloth.
2Deep grooves or signs of pick-up (especially on
the lower sealing portion of the piston) will require
replacement of the component. Examine seal on
feeder D, replace if necessary.
3Examine the check valve ball F and ball seats for
signs of damage or excessive wear. Obtain new
components if necessary.
4Examine the seals for signs of wear. Pay
particular attention to their lips. Obtain new seals
if necessary or if the piston is changed.
5Examine the housing cap Gand spool H for
signs of damage. Obtain new components if
necessary.
6Examine the plug K, seal washer L, spring and
trigger spool Mfor signs of damage or wear.
Obtain new components if necessary.
AA
CC
DD
AA
CC
DD
FF
HH
GG
MM
LL
KK
JJ
JJ

B7 MAINTENANCE
9803/1250
B7
Issue 1
BREAKER INSPECTION - HM 22, 25, 29 (cont’d)
7Examine the roll pins Q, latch R, latch plunger S
and plunger spring for signs of damage or wear.
Obtain new components if necessary.
8Should it be necessary to remove the
components of the tool bushing, firstly push in
the spring ring aa with a sharp instrument via the
hole shown at cc.
9Grip the spring ring aa with a suitable pair of
pincers ee and remove. The sliding bush and
other components can now be removed from the
nose (see item 10).
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 diaphragm insert. Replace as
necessary.
QQ
SS
RR
aa
ee
aa
ii
jj
nn
ff
XX
cc
aa
Note: A hydraulic press will be required to remove to
remove the steel tool bush nn. See item 10.

B8 MAINTENANCE
9803/1250
B8
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29
Note: During assembly, apply Multi Gasket Loctite
518 (JCB Part No. 4102/1212) to all joint faces. Use
new seals and ‘O’ rings throughout.
1Place diaphragm Xinto the head, ensuring that
the diaphragm insert is uppermost (as shown
above). Fit new ‘O’ ring seal Y.
2Fit the trigger spool M, spring, seal washer Land
plug Kinto the head J. Fit seal on head unit J.
3 Fit the trigger pin Ointo the handle bracket. Fit
the handle bracket to the head. Treat the threads
of the safety screw Vwith Loctite 270 and fit to
the head.
4Fit 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.
5The illustration above shows the trigger handle
after coating with a suitable lubricant before
fitting.
!CAUTION
Before commencing assembly, all components
must be scrupulously cleaned.
A-3-1-4
XX
YY
KK
LLMM
JJ
OO
VV

B9 MAINTENANCE
9803/1250
B9
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)
6Treat the thread of the pivot pin Zwith Loctite
270 and fit the pin where indicated.
7Check that all parts of the trigger and other parts
in contact are well coated with lubricant. (see
item 5)
8Fit the housing spool Hand the housing seal G
into the head J. Fit a new ‘O’ ring to the housing
seal G.
9Assemble 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 Fis clean and
undamaged. Obtain a new seal. Assemble the
check valve.
11 Fit the check valve into the barrel A. Always
ensure that ball Fhas been fitted.
ZZ
ZZ
GG
JJ
HH
ss
zz
A
EE
FF
FF
EE
EE
AA
tt

MAINTENANCE
9803/1250
B10
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)
12 Bolt the barrel Ato the nose B. Torque tighten
the capscrews progressively using a Gedore
narrow head torque wrench (part no. 7200-01).
See Torque Figures on Page A2
13 Fit 3 new seals into barrel A. Insert the piston C
and piston feeder Dinto the barrel A.
14 Fasten the barrel A/nose Bassembly 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).
AA
BB
DDCC
AA
AA
BB
NN
B10

B11 MAINTENANCE
9803/1250
B11
Issue 1
CHARGING THE ACCUMULATOR - HM 22, 25, 29
X3
743310
!WARNING
Use only nitrogen gas to charge the accumulators. The
use of any other gas can cause the accumulators to
explode. Remember that although nitrogen is not
poisonous, you can be killed by suffocation if it displaces
air in your workplace. Do not allow excessive quantities
of nitrogen to be discharged into the atmosphere.
This procedure must not be carried out with the breaker
(or pick) connected to a source of hydraulic supply.
During charging, the breaker must be securely mounted
in the upright position. This prevents the breaker falling
over whilst charging, thereby preventing uncontrolled
escape of gas.
EQUIPMENT REQUIRED.
a Nitrogen bottle
Minimum residual pressure 70 bar (1000lbf/in2)
b Regulator (with contents and outlet gauge)
Outlet pressure should be controllable up to 55 bar
(800 lbf/in2)
c Charging adaptor (JCB part no. 929/05800)
together with 3/8 in. BSP Dowty washer.
d Connecting hose
Suitable hose of minimum operating pressure 207 bar
(3000 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
1Remove the slotted cover screw 1from the breaker.
2Using a 4 mm. Allen key 2, slowly loosen the charging
screw approximately 3 turns. Do not remove the screw.
3Fit the 3/8 in. Dowty washer 5to the charging adaptor 3
and screw into the breaker. Do not overtighten, hand
tight is adequate.
4Ensure that the nitrogen bottle outlet pressure is at zero
and then connect the charging hose 4to the charging
adaptor 3.
5Gradually increase the nitrogen bottle outlet pressure
until the required level is reached (see Specification
section).
6Push in knob 6on the charging adaptor 3 to engage the
charging screw and tighten. Do not overtighten.
7Shut the regulator valve on the nitrogen bottle and using
the venting screw 7, release the trapped gas in the
hose.
8Disconnect the charging hose 4and unscrew the
charging adaptor 3from the body of the breaker.
9Finally, tighten the charging screw using a 4mm. Allen
key 2and refit the cover screw 1after applying Loctite
270 to the threads.
44
3322
6677
11
55

B12 MAINTENANCE
9803/1250
B12
Issue 1
OPERATOR FAULT FINDING
Specifications
*The remedy in certain cases should be carried out by your JCB dealer
Symptom Possible Fault Remedy
Breaker fails to operate. No flow from supply. *Check output with flow and pressure tester.
Hoses incorrectly fitted. Check that pressure feed is connected to
top port on the breaker.
Insufficient movement of *The trigger spool should move approx.
trigger spool. 5mm (0.2in.). Check lever mechanism.
Main spool jammed or *Remove and check.
damaged. Clean all associated parts.
Striker piston seized. *Remove and check for 'pick-up' on piston feeder or
barrel. Replace any damaged parts.
Breaker lacks breaking power. Insufficient available *Check Main Relief Valve -
pressure. minimum setting 76 bar (1100 lbf/in2) for the 22 kg
Breaker and 110 bar (1595 lbf/in2) for the 25 and
29 kg Breaker.
Low accumulator gas pressure *Re-charge the accumulator
(Normally associated with
violent shaking of hoses).
Hexagon bush in nose Apply JCB Retainer( High Strength ) and press back.
casting loose.
Breaker runs slow Insufficient flow. *Check that 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 Check oil supply has adequate cooling.
hydraulic oil. Temperature should not exceed
80C (176F).
Noise Level Standard:
Noise Level EC Directive 84/537/EEC (Lwa)
Vibration Standard:
Vibration Weighted RMS Acceleration ISO 8662 Part 5 (m/s2)
Min. Acc.
EHTMA Pressure Relief Valve Gas
Model Length Weight Steel Size mm (in) Noise Level Vibration Category Flow Rate Range Settings Pressure
929/92400 760 mm 25 kg 32 x 160 (11/4 x 61/4) 109 Lwa 4.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 43 bar
929/92500 720 mm 22 kg 22 x 82.5 (7/8 x 31/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92600 680 mm 22 kg 25 x 108 (1 x 41/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92700 730 mm 29 kg 32 x 160 (11/4 x 61/4) 108 Lwa 5.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 50 bar
929/92900 730 mm 29 kg 32 x 160 (11/4 x 61/4) 110 Lwa 5.9 m/s 2 D 28-32 L/Min 90-110 bar 110 bar 50 bar

B13 MAINTENANCE
9803/1250
B13
Issue 1
BREAKER HM26 (NON EU)

B14 MAINTENANCE
9803/1250
B14
Issue 1
BREAKER HM26 (NON EU)
HM26 (NON EU) - Servicing
It should be noted that, when servicing this breaker
(shown on page B12), detail for the handle only
reference should be made to Section C - Standard
handle breakers(from 9803/1250 Issue 1).
The remainder of the breaker , head, barrel and nose
sections, are covered in Section B - respective
sections.