JCB HM Range Medium and Large Hydraulic Breakers Service Repair Manual SN1095001 - PDF DOWNLOAD

Service Manual HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 onwards Published by JCB Attachments Waterloo Park, Beamhurst Uttoxeter, Staffordshire ST14 5PA England Tel: +44 (0)1889 506043 PRINTED IN ENGLAND

Publication No. 9803/1420_04

HM Medium Breakers

1

HM Large Breakers

2

Service Manual Section 1 - Medium Breakers

Publication No.

9803/1420-04

World Class Customer Support Copyright Š 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

Notes:

0

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Contents Page No. Medium Breakers Introduction .................................................................................................... 1 Safety ....................................................................................................... 1 General Information .................................................................................. 1 Workshop Standards ................................................................................ 1 Spare Parts ............................................................................................... 1 Service Personnel .................................................................................... 1 Using this Manual ..................................................................................... 2 Standard Symbols ......................................................................................... 3 Service Tools ................................................................................................. 5 Charging Equipment .................................................................................... 10 Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling .................................................................................................. 11 Assembly ..................................................................................................... 18 Field Bushing Exchange .............................................................................. 23 Charging the Accumulator ........................................................................... 25 Hanger Brackets .......................................................................................... 27 Exploded Views ........................................................................................... 28 Operating Principles .................................................................................... 32 Stage 1 - Start Up ................................................................................... 32 Stage 2 - Return Stroke .......................................................................... 32 Stage 3 - Power Stroke ........................................................................... 33 Stage 4 - End of Power Stroke ............................................................... 33 Medium Breakers - HM386Q Special Tools ............................................................................................... 34 Dismantling .................................................................................................. 38 Assembly ..................................................................................................... 45 Operating Principles .................................................................................... 54 Stage 1 ................................................................................................... 54 Stage 2 ................................................................................................... 54 Stage 3 ................................................................................................... 55 Stage 4 ................................................................................................... 55 Stage 5 ................................................................................................... 56 Medium Breakers Technical Specifications .............................................................................. 57 Nitrogen Adaptor Reference Chart .............................................................. 58 Tool Part Numbers ....................................................................................... 63 Breaker Part Number Matrix ........................................................................ 64

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Medium Breakers Introduction Safety 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.

The words WARNING and CAUTION have the following meanings:

Any unauthorised use or copying of the contents of this manual or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

Workshop Standards JCB HM Breakers have hydraulically powered percussion mechanisms. Since all hydraulically powered equipment is sensitive to dirt, the breakers must always be disassembled in a place that is:

!MWARNING

– Isolated from all dust and particle-generating activities such as grinding and welding.

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

– Equipped with washing facilities and compressed air for the blow cleaning of components.

– Equipped with all the necessary standard and special tools.

INT-1-2-2

!MCAUTION 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

General Information The following instructions are intended to guide service personnel in the repair or overhauling of the JCB Medium Breakers.

!MWARNING NEVER intervene in the breaker when it is connected to the hydraulic system, or when the accumulator is charged.

TTG

All users of this manual are asked to inform JCB Attachments if they find any errors or discrepancies, especially any affecting product safety.

1

– Very clean, i.e. free of dust and dirt.

!MWARNING The tool must not be modified without the manufacturer’s permission. Use only original parts and accessories approved by JCB Service. If modifications are made that are not approved by JCB Service, serious harm to yourselves or others may result.

TTG

Spare Parts Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts will not be covered by any warranty or product liability.

Service Personnel This manual is designed for the benefit of JCB Distributer Service Engineers who are receiving, or have received, training by the JCB Training Centre or by JCB Service Personnel. These personnel should have a sound knowledge of workshop practice, safety procedures and general techniques associated with the maintenance and repair of hydraulic equipment.

9803/1420-04

1

Medium Breakers Introduction Renewal of seals, gaskets etc. and any components showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.

Finally, please remember above all else - SAFETY MUST COME FIRST!

Using this Manual This manual begins with a list of the symbols and tools used in the overhaul procedures. This is followed by instructions on how to dismantle the breaker into its component parts, the checking and inspection of parts, and then reassembly.

2

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Medium Breakers Standard Symbols

Standard Symbols

3

Important positional relationship

Direction

Inspect and replace damaged parts

New parts

To be avoided

Okay

Force

Turning to end position

Oil

Loctite 243

Gas release

Scrap

Contact sound

Minutes

Grease

Frozen

9803/1420-04

3

Medium Breakers Standard Symbols

Torque

4

On the excavator

Cracks

9803/1420-04

In turn

4

Medium Breakers Service Tools

Service Tools Use this as a checklist before working on the breakers.

Item

Description Plastic hammer

Allen socket: 5, 8, 14 mm

Screwdriver

Punch 10 mm

Torque wrench 0 - 650 Nm

Allen sockets for torque wrench: 5, 6, 8, 10, 14 mm

Vernier gauge

Ratchet wrench

5

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Medium Breakers Service Tools Item

Description Scriber

Open-ended spanners: 13, 14, 15, 17, 19, 24, 27, 30, 36 mm

Sockets for torque wrench: 17, 24, 30, 36 mm

Circlip pliers

Slide hammer

6

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7

Item

Part No. 998/11247

Description Shackle

HM165Q Disassembly/assembly of piston and liner

HM265Q

HM365Q

HM495Q

z

z

z z z z z z z

z z z z z z z

z z z z z z z

z z z

Comprises of: 998/11228

Extractor assembly

1370/0901

M24 Nut

998/11229

Screw

998/11230

Foot

998/11231

Disk

998/11232

Tube

998/11245

Extractor

Removal of piston guide

Comprises of: 9803/1420-04

998/11217

Handle

998/11218

Weight

998/11219

Pull rod

998/11220

Disk

826/00920

Roll pin

2203/0012

M10 Circlip

1370/0301

M10 Nut

998/11221

Disk

TBA

Mandrel

z z z z

Fitting of liner assembly

Medium Breakers

Service Tools

7

8

Item

Part No.

Description

HM165Q

TBA

Extractor

Removal of bushing

998/11253

Mandrel

Assembly of bushing

HM265Q

HM365Q

HM495Q

z z

998/11254

9803/1420-04

TBA

Assembly tool

Helicoil thread inserts

998/11249

Removal tool

Removal of tool bushing

F z

Comprises of: Screw

998/11236

Threaded Tube

998/11237

Tube

z z z Service Tools

8

Medium Breakers

998/11235

9

Item

Part No.

Description

998/11246

Removal tool

HM165Q

HM265Q

HM365Q

HM495Q

z

Removal of bushing

Comprises of: 998/11222

Core

998/11223

Handle

998/11224

Sleeve

998/11225

Sleeve

998/11226

Striker

998/11227

M25 Pin

1391/3405

Bolt M10 x 20

998/11240

Mandrel

z z z z z z z z z

998/11241 9803/1420-04

998/11242

Drift

Rear wiper seal

z

Medium Breakers

Service Tools

9

Medium Breakers Charging Equipment

Charging Equipment Item

10

Part No.

Description

TBA

Charging hose complete with adaptor

Hose for charging accumulators

998/11322 998/11365

Gas regulator complete with pressure gauge

Charging of high pressure and low pressure accumulators

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

1420_107

11

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

1420_108

12

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

1420_109

13

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

HM165Q HM265Q HM385Q HM495Q

mm 37.900 44.900 62.400 69.300

mm 46.995 64.920 74.950 84.340

mm 44.940 53.930 72.950 81.940

mm 1.5 1.5 1.5 1.5 1420_110

14

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

1420_111

15

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

HM165Q HM265Q 100 Nm HM385Q 150 Nm HM495Q 300 Nm

1420_112

16

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Dismantling

HM385Q < 83 mm HM165Q < 53 mm HM385Q > 83 mm HM165Q > 53 mm HM495Q < 98 mm HM265Q < 68 mm HM495Q > 98 mm HM265Q > 68 mm

HM385Q - O 72 mm HM495Q - O 85 mm HM165Q - O 55 mm HM265Q - O 70 mm

1420_113

17

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Assembly

Assembly

1420_114

18

9803/1420-04

18

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Assembly

1420_115

19

9803/1420-04

19

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Assembly

3â&#x20AC;? #

1420_116

20

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Assembly

HM385Q 300 Nm HM495Q 650 Nm HM165Q HM265Q 200 Nm 1420_117

21

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Assembly

HM385Q HM495Q 190 Nm

HM265Q 120 Nm HM165Q 75 Nm

1420_118

22

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Field Bushing Exchange

Field Bushing Exchange

1420_119

23

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Field Bushing Exchange

1420_120

24

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Charging the Accumulator

Charging the Accumulator

1420_123

25

9803/1420-04

25

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Charging the Accumulator

1420_124

26

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Hanger Brackets

Hanger Brackets If the breaker hanger bracket is changed, ensure it has the correct orientation. Later hanger brackets have a cross welded to the side plate denoting the dipper pivot.

Model

Table 1. Tightening Torque Bolt Size

HM165Q, 265Q, 385Q, 495Q

M16

200 Nm(1)

(1) For bolts used with nord-lock washers and thread inserts. If a non JCB hanger bracket is used, refer to the relevant manufacturers documentation.

27

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Exploded Views

Exploded Views Tightening torque Pos Pos Pos Pos Pos Pos Pos

5 6 13 17 18 37 56

22 21 19

18

= 95 Nm = 40 Nm = 30 Nm = 75 Nm = 75 Nm = 200 Nm = 200 Nm

13

14

24

12

11

23

22 21 20

15 16

23

25

10 9

26 8 7 28

27

17

3 5

6

2

29 31

1

32

7

34

33 56

30

43 4 35

37 36

36

40 Atlas Copco Berema AB

42

NACKA SWEDEN

Type TEX 110 H Ser No 1234567890

39

Pmax

bar(e)

!

xxxx xxxx xx

i Made in Sweden

38

41

53

44 45 46 47

48

46

49

51

Fig 1. HM165Q

28

9803/1420-04

51 46 52

54

46 55 56 1420_127

28

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Exploded Views

Tightening torque Pos Pos Pos Pos Pos Pos Pos Pos Pos Pos Pos

5 12 13 17 22 30 31 35 37 38 55

= = = = = = = = = = =

95 Nm Loctite 243 40 Nm Loctite 243 120 Nm 30 Nm 120 Nm 100 Nm 200 Nm 30 Nm 15 Nm Loctite 270 25 Nm Loctite 243 200 Nm

14 16

13

17

18

15 98

7

10 19 20

6 32

21

12

Atlas Copco Berema AB NACKA SWEDEN

Type TEX XXX Ser No 1234567890

23 22

11 5

3

2

Pmax 7 bar(e) xxxx xxxx xx

!

i

Made in Sweden 199x

56

24

25 27 28

1

29

26

61 60

30 31

4

59

38

58

35

36

38

55 54 34

54

53

33

37

5

57

49

39 40 41

42

43

46 44

29

45

48 44 45

Fig 2. HM265Q

29

47

9803/1420-04

50

52 45 44 51 1420_128

29

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Exploded Views

Fig 3. HM385Q

30

9803/1420-04

1420_125

30

Medium Breakers - HM165Q, 265Q, 385Q, 495Q

Tightning torque

Exploded Views

Fig 4. HM495Q

31

9803/1420-04

1420_126

31

Medium Breakers - HM165Q, 265Q, 385Q, 495Q Operating Principles

Operating Principles Stage 1 - Start Up

Stage 2 - Return Stroke

Fig 6.

Fig 5.

1420_129a

When the hammer is started, the front cylinder chamber is pressurised. At the same time, the accumulator and the pins B, which give a holding force on the main valve C, are pressurised via the channel A. This causes the piston to begin its return stroke.

32

1420_130a

When the rear edge of the piston meets the main valve C, the holding force is overcome and the valve moves backwards.

When the front edge of the valve uncovers port D, the front edge becomes pressurised, causing the valve to move backwards more rapidly than the piston. The rear cylinder chamber is now pressurised. This causes the piston to begin its working stroke because of the difference in the front and rear piston pressure areas.

9803/1420-04

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Medium Breakers - HM165Q, 265Q, 385Q, 495Q Operating Principles

Stage 3 - Power Stroke

Fig 7.

Stage 4 - End of Power Stroke

1420_131a

The job of the accumulator is to keep the pressure at maximum level during the working stroke of the piston.

When the rear edge of the piston uncovers port E, the back of the valve becomes pressurised. This causes the valve to move forward and close port D.

Fig 8.

1420_132a

At the same time as the valve closes port D, port F is uncovered. Now only the front cylinder chamber is pressurised, which causes the piston to make another return stroke.

When this happens, the hydraulic oil in the rear cylinder chamber flows back to the tank via the return line.

33

9803/1420-04

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Medium Breakers - HM386Q Special Tools The following tools are special tools required for dismantling and assembly of the breaker. These tools can be manufactured locally from the drawings shown.

ST1

1420_7a

34

9803/1420-04

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Medium Breakers - HM386Q Special Tools

ST2

M10 x 130 full threaded

For removal of back head

1420_7b

ST3

1420_8a

35

9803/1420-04

35

Medium Breakers - HM386Q Special Tools

ST4

1420_8b

ST5 M6 x 120

E

1420_9a

36

9803/1420-04

36

Medium Breakers - HM386Q Special Tools

ST6

1420_9b

ST7

6.3

( ) 1.6

115

NO HARDENED

15

1x45°(2x) M12

5°

Ø25

20

EDGE BROKEN

2

1.6

20

60

R8

1.6

15

M12

1.6

R2 (2x) 30°

Ø40 Ø61.5f7

8° NITROCARBURIZED

SS2541 1420_10

37

9803/1420-04

37

Medium Breakers - HM386Q Dismantling

Dismantling 1.

3.

2.

4.

ST1

1420_15

38

9803/1420-04

38

Medium Breakers - HM386Q Dismantling

5.

6.

7.

Warning The accumulator is pressurized even when the hydraulic system is shut off. Disassembling the accumulator before letting the gas out can cause injury!. â&#x2013;ş Let the gas out slowly by opening the charging valve. â&#x2013;ş Make sure that there is no gas pressure in the accumulator before disassembling the accumulator housing.

1420_16

39

9803/1420-04

39

Medium Breakers - HM386Q Dismantling

8.

11.

12.

9.

13.

10.

1420_17

40

9803/1420-04

40

Medium Breakers - HM386Q Dismantling

14.

17.

18.

15.

19.

16.

1420_18

41

9803/1420-04

41

Medium Breakers - HM386Q Dismantling

20.

23.

21.

24.

22.

25.

1420_19

42

9803/1420-04

42

Medium Breakers - HM386Q Dismantling

26.

27.

28.

1420_20

43

9803/1420-04

43

Medium Breakers - HM386Q Dismantling

29.

32.

33.

30.

31.

34.

1420_21

44

9803/1420-04

44

Medium Breakers - HM386Q Assembly

Assembly 35.

37.

36.

38.

1420_22

45

9803/1420-04

45

Medium Breakers - HM386Q Assembly

39.

41.

42.

40.

43.

1420_23

46

9803/1420-04

46

Medium Breakers - HM386Q Assembly

44.

46.

45.

1420_24

47

9803/1420-04

47

Medium Breakers - HM386Q Assembly

47.

50.

51.

48.

49.

1420_25

48

9803/1420-04

48

Medium Breakers - HM386Q Assembly

52.

53.

54.

1420_26

49

9803/1420-04

49

Medium Breakers - HM386Q Assembly

55.

57.

58.

56.

59.

1420_27

50

9803/1420-04

50

Medium Breakers - HM386Q Assembly

60.

63.

Warning The accumulator must only be charged with Nitrogen (N2). Other gases can cause explosions.

61.

64.

62.

1420_28

51

9803/1420-04

51

Medium Breakers - HM386Q Assembly

65.

66.

67.

1420_29

52

9803/1420-04

52

Medium Breakers - HM386Q Assembly

68.

69.

1420_30

53

9803/1420-04

53

Medium Breakers - HM386Q Operating Principles

Operating Principles Stage 1

Stage 2

Fig 1.

1420_S1

Pressurised oil comes from the excavator pump. The pressure is limited to 150 bar by the built in pressure relief valve.

Fig 2.

1420_S2

During the return stroke the pressure lifts the diaphragm support. This compresses the gas in the accumulator to the same level as the oil pressure.

The pressure lifts the control valve to its upper position and the upper end of the piston is connected to tank.

At the same time the lower end of the piston gets pressurised from the pump, causing the piston to start the return stroke.

54

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Medium Breakers - HM386Q Operating Principles

Stage 3

Stage 4

Fig 3.

1420_S3

When the piston is in its top position, the lower end of the piston allows for a signal pressure to reach the top side of the control valve, causing it to move to its lower position.

The inlet oil now passes through the control valve, putting pressure on the top end of the piston. The piston starts the impact stroke.

55

Fig 4.

1420_S4

During the impact stroke, the piston traps the signal pressure to the control valve, causing it to remain in its lower position. The oil and gas pressure in the accumulator help keeping the hydraulic pressure up during the impact stroke.

9803/1420-04

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Medium Breakers - HM386Q Operating Principles

Stage 5

Fig 5.

1420_S5

When the piston hits the chisel, the control section of the piston connects the signal channel from the control valve to tank, allowing the control valve to move back to its upper position.

The hydraulic oil at the upper end of the piston becomes connected to tank and loses its pressure. The lower end of the piston is still under pressure, making the piston start the return stroke again.

56

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57

Medium Breakers Technical Specifications Model

HM165Q

HM265Q

HM385Q

HM386Q

HM495Q

120 kg (265 lb)

200 kg (441 lb)

312 kg (688 lb)

328 kg (722 lb)

419 kg (924 lb)

Serial No. from

1095001 onwards

1095001 onwards

1095001 onwards

TBA

1095001 onwards

Recommended carrier class

1.2 - 3.2 tonne (2645 70548 lb)

2.5 - 8 tonne (5512 17637 lb)

5 - 8.5 tonne (11023 18740 lb)

5 - 8.5 tonne (11023 18740 lb)

6 - 10 tonne (13228 22046 lb)

Service weight

(1)

Impact rate

540 - 1080 blows/min

900 - 1750 blows/min

480 - 960 blows/min

720 - 1380 blows/min

390 - 780 blows/min

Impact energy (calculated)

306 Joules

516 Joules

859 Joules

829 Joules

1058 Joules

Length (excluding tool)

710 mm (28 in)

713 mm (28.1 in)

850 mm (33.5 in)

875 mm (34.4 in)

925 mm (36.5 in)

Oil flow rate

20 - 40 l/min

30 - 65 l/min

50 - 80 l/min

60 - 100 l/min

50 - 90 l/min

(4.4 - 8.8 UK gal/min)

(6.6 - 14.3 UK gal/min) (11 - 18 UK gal/min)

(13 - 22 UK gal/min)

(11 - 22 UK gal/min)

9803/1420-04

(13 - 26.5 US gal/min)

100 - 150 bar (1450 2176 psi)

100 - 150 bar (1450 2176 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

Static pressure to be set at 20 bar (290 psi) above measured operating pressure.

Maximum return line pressure

20 bar (290 psi)

20 bar (290 psi)

20 bar (290 psi)

35 bar (500 psi)

20 bar (290 psi)

50 mm (1.97 in)

65 mm (2.6 in)

80 mm (3.15 in)

80 mm (3.15 in)

95 mm (3.75 in)

H.P. accumulator (Minimum gas pressure)

40 bar (580 psi)

40 bar (580 psi)

40 bar (580 psi)

40 bar (580 psi)

40 bar (580 psi)

Sound pressure level measured r - 10 m (32.8 ft)

95 L dB (A)

90 L dB (A)

96 L dB (A)

93 L dB (A)

100 LP dB (A)

Sound power level guaranteed(3)

124 LWA dB (A)

118 LWA dB (A)

125 LWA dB (A)

121 LWA dB (A)

129 LWA dB (A)

Connecting threads on ports ‘P’ and ‘T’

1/2” BSP

1/2” BSP

3/4” BSP

3/4” BSP

1” BSP

- Hoses

12.5 mm (0.5 in)

19 mm (0.75 in)

19 mm (0.75 in)

19 mm (0.75 in)

25 mm (1 in)

- Pipes

12.5 mm (0.5 in)

19 mm (0.75 in)

19 mm (0.75 in)

19 mm (0.75 in)

25 mm (1 in)

Tool diameter (2)

P

100 - 150 bar (1450 2176 psi)

P

100 - 150 bar (1450 2176 psi)

P

P

Inside diameter

57

(1) Hydraulic breaker including breaker housing, tool and medium size hanger bracket.

(2) Depending on oil flow rate.

(3) At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure on the tool. Measuring process based on directive 2000/14/EC.

Medium Breakers

(16 - 26.5 US gal/min)

100 - 150 bar (1450 2176 psi)

Technical Specifications

(5.3 - 10.6 US gal/min) (8.0 - 17.2 US gal/min) (13 - 21 US gal/min) Operating pressure

Medium Breakers Nitrogen Adaptor Reference Chart

Nitrogen Adaptor Reference Chart Country

Adaptor

Part No.

Algeria

40h

892/01202

Argentina

40b

892/01196

Armenia

40n

892/01207

Australia

40b

Austria

892/01207

Bahamas

40b

892/01196

Bahrain

40h

892/01202

Bangladesh

40b

892/01196

Barbados

40b

892/01196

Direct (1)

-

Bolivia

40g

892/01201

Botswana

40b

892/01196

Brazil

40g

892/01201

Bulgaria

40n

892/01207

Burma

40b

892/01196

Canada

40c Direct

892/01201

China

40k

892/01204

Columbia

40g

892/01201

40b

892/01196

Czech Republic

Direct (1)

-

Denmark

Direct (1)

-

Djibouti

40h

892/01202

Dom. Republic

40g

892/01201

Ecuador

40g

892/01201

Egypt

40b

892/01196

Ethiopia

40b

892/01196

Fiji

40b

-

40h

892/01202

40h

892/01202

40h

892/01202

Direct (1)

-

40b

892/01196

892/01196 -

Finland

Direct

France

40h

892/01202

Gabon

40h

892/01202

Gambia

40b

892/01196

Georgia

40n

892/01207

Direct

Direct (1)

-

40g

Germany

-

892/01197 (1)

Chile

Costa Rica

Direct (1)

-

40n

Chechenya

Part No.

892/01196 (1)

Azerbaijan

Belgium

58

Direct

Alternative Adaptor

(1)

(1)

-

Ghana

40b

892/01196

Great Britain

40b

892/01196

Greece

40h

892/01202

Guatemala

40g

892/01201

Guinea

40h

892/01202

9803/1420-04

58

Medium Breakers Nitrogen Adaptor Reference Chart Country

Part No.

Guyana

40g

892/01201

Honduras

40g

892/01201

Hong Kong

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

Liechtenstein

Direct

Luxembourg

Direct

(1)

-

Malawi

40b

892/01196

Malaysia

40l

892/01205

Malta

40b

892/01196

Mauritius

40h

892/01202

Mexico

40h

892/01202

Moldova

40n

892/01207

Morocco

40h

892/01202

Mozambique

40h Direct

New Zealand

40b

Nigeria

40h

Norway

Direct

Alternative Adaptor

Part No.

40f

892/01200

Direct (1)

-

Direct (1)

-

40b

892/01196

Direct (1)

-

892/01202 (1)

Netherlands

59

Adaptor

892/01202 (1)

892/01196 892/01202

(1)

-

9803/1420-04

59

Medium Breakers Nitrogen Adaptor Reference Chart Country

Adaptor

Part No.

Oman

40h

892/01202

Pakistan

40b

892/01196

Paraguay

40g

892/01201

Peru

40g

892/01201

Philippines

40b

892/01196

Direct (1)

-

Portugal

40b

892/01196

Puerto Rico

40c

892/01197

Poland

Part No.

40o

892/01208

Qatar

40k

892/01204

Romania

40h

892/01202

Russia Federation

40n

892/01207

Direct (1)

-

Saudi Arabia

40h

892/01202

40b

892/01196

40i

892/01203

40n

892/01207

Singapore

40b

892/01196

Slovakia

Direct (1)

-

Slovenia

Direct (1)

-

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

(1)

-

Switzerland

Direct (1)

-

Syria

40h

892/01202

Taiwan

40b

892/01196

Tanzania

40b

892/01196

Thailand

40b

892/01196

Trinidad/Tobago

40m

892/01206

Tunisia

40h

892/01202

Turkey

40b

892/01196

Direct (1)

-

Turkmenistan

Direct

(1)

-

Direct (1)

-

40n

892/01207

Direct (1)

-

United Arab Emirates

40h

892/01202

Uruguay

40g

892/01201

Ukraine

60

Alternative Adaptor

USA

40c

892/01197

Uzbekistan

40n

892/01207

Venezuela

40n

892/01207

9803/1420-04

60

Medium Breakers Nitrogen Adaptor Reference Chart Country

Adaptor

Part No.

Vietnam

40b

892/01196

Zambia

40b

892/01196

Alternative Adaptor

Part No.

(1) Direct means an additional adaptor is not required for connecting the regulator to the gas bottle.

61

9803/1420-04

61

Medium Breakers Nitrogen Adaptor Reference Chart

892/01208

62

892/01205

892/01206

892/01207

892/01202

892/01203

892/01204

892/01199

892/01200

892/01201

892/01196

892/01197

892/01198

9803/1420-04

62

Medium Breakers Tool Part Numbers

Tool Part Numbers Model

Description

mm

in

mm

in

mm

in

mm

in

HM165Q

Moil

50

1.97

510

20.08

310

8.27

-

-

331/52394

Narrow chisel

50

1.97

510

20.08

310

12.2

-

-

331/52395

Wide chisel

50

1.97

480

19

280

11.02

125

4.92

331/52396

Wide chisel transverse

50

1.97

480

19

280

11.02

125

4.92

331/52397

Asphalt cutter

50

1.97

490

19.29

290

11.42

115

4.53

331/52399

Asphalt cutter transverse

50

1.97

490

19.29

290

11.42

115

4.53

331/52400

Blunt

50

1.97

510

20.08

310

12.2

-

-

331/52398

Moil

65

2.56

600

23.62

320

12.6

-

-

331/52496

Narrow chisel

65

2.56

600

23.62

320

12.6

-

-

331/52497

Wide chisel

65

2.56

650

25.6

370

14.57

125

4.92

331/52498

Wide chisel transverse

65

2.56

650

25.6

370

14.57

125

4.92

331/52499

Blunt

65

2.56

600

23.62

320

12.6

80

3.15

331/52500

Moil

80

3.15

800

31.5

470

18.5

-

-

331/52461

Moil

80

3.15

1000

39.37

675

26.57

-

-

331/52462

Narrow chisel

80

3.15

800

31.5

470

18.5

-

-

331/52464

Wide chisel

80

3.15

770

30.31

445

17.52

160

6.3

331/52467

Wide chisel transverse

80

3.15

770

30.31

445

17.52

160

6.3

331/52468

Blunt

80

3.15

800

31.5

470

18.5

-

-

331/52493

Moil

95

3.74

840

33.07

460

18.11

-

-

331/52501

HM265Q

HM385Q, 386Q

HM495Q

Diameter

Overall Length

Working Length

Tip Width

Part No.

Moil

95

3.74

1200

47.24

820

32.28

-

-

331/52502

Narrow chisel

95

3.74

840

33.07

460

18.11

-

-

331/52503

Wide chisel

95

3.74

800

31.5

415

16.34

180

7.09

331/52504

Blunt

95

3.74

840

33.07

460

18.11

-

-

331/52505

A standard chisel or asphalt cutter is supplied with the cutting face perpendicular to the boom. A parallel chisel or asphalt cutter has the cutting face parallel with the boom.

A range of steels are available to meet all applications. They are manufactured from high quality materials for long life.

– MOIL: For layered rock and reinforced concrete, where twisting could occur.

– PYRAMID POINT: All moils above 100 mm diameter.

– CHISEL: Standard tool for penetrative work. E.g. Mining, foundations, trenching, demolition.

– BLUNT: For impact breaking. E.g. Mining, breaking oversizes, demolition.

63

9803/1420-04

63

Medium Breakers Breaker Part Number Matrix

Breaker Part Number Matrix Model HM165Q

HM265Q

HM385Q

HM386Q

HM495Q

64

Machine

Part No. Rest of World

North America

803, 804

980/90237

980/90301

802

980/90253

980/90302

UNIVERSAL

980/90256

980/90303

ROBOT

980/90355

980/90368

1CX

980/90453

N/A

208

N/A

980/90456

MIDI CX

980/90867

980/90868

8020

980/A2706

980/A2731

802

980/90241

980/90304

803, 804

980/90242

980/90305

UNIVERSAL

980/90257

980/90306

3CX RUSSIAN SPECIAL

980/90513

N/A

8052

980/90243

980/90307

8045

980/90286

980/90308

ROBOT

980/90366

980/90309

8052, 8080

980/90238

980/90309

3CX, 4CX

980/90239

980/90310

JZ70

980/90240

980/90311

UNIVERSAL

980/90258

980/90312

ROBOT

980/90367

980/90371

8052, 8080

980/A3477

-

3CX, 4CX

980/A3478

-

JZ70

980/A3480

-

UNIVERSAL

980/A3481

-

ROBOT

980/A3483

-

8080

980/90244

980/90313

3CX, 4CX

980/90245

980/90314

JZ70

980/90246

980/90315

UNIVERSAL

980/90259

980/90316

9803/1420-04

64

Service Manual HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 onwards Section 2 Large Breakers

Publication No.

9803/1420-04

World Class Customer Support Copyright Š 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 Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Page left intentionally blank

9803/1420-04

Large Breakers - Contents Chapter

Title

Page

Introduction 1

General

1

1.1

Explanation of the symbols in the repair manual

1

2

Operational safety

2

2.1

General

2

2.2

Accident prevention regulations

2

2.3

Safety Notices

3

Tools

5

3.1

General tools

5

3.2

Service box

6

3.3

Special accessories

7

3.3.1

Accumulator charging device

7

3.3.2

Power wrench

8

3.3.3

HeliCoil-tools

8

3.3.4

Fitting aid for piston

9

3.3.5

Press-out aid for wear bushes

9

3.4

Consumables

Safety

Tools 3

10

Technical Specifications 4

Technical Specifications

11

4.1

Breaker Specifications

11

4.2

Working Pressure/Required Flow/Engine RPM

16

5

Dismantling the Hydraulic Breaker

21

5.1

Fitting/Removing the Tool

21

5.2

Removing the Power Cell from the Hammer Housing

22

5.3

Removing the High-Pressure Accumulator

23

5.4

Removing the Control System

24

5.5

Removing the Control Slide Valve

24

5.6

Removing the Frequency Switching System

25

5.7

Removing the Cylinder Cover

26

5.8

Removing the Piston and sealing Bush

28

5.9

Removing the Cylinder

28

5.10

Removing the Locking Pins for the Retainer Bars in the Lower Breaker Part

29

5.11

Removing the Locking Bushes

29

6

Checking the Hammer Housing

30

6.1

Checking for Cracks and Indentations

30

Dismantling

Checking

i

9803/1420-04

i

Large Breakers - Contents Chapter

Title

6.2

Wear to the Bottom Plate

Page 30

6.3

Checking the Elastic Pad

31

6.4

Checking the Damping Elements

31

6.5

Checking the Guide Plates

32

6.6

Checking the Tool for Wear

33

7

Assembling the Hydraulic Hammer

34

7.1

Tightening Torques for Screws and Screw Couplings on the JCB HM 860Q

34

7.2

Tightening Torques for Screws and Screw Couplings on the JCB HM 1260Q

35

7.3

Tightening Torques for Screws and Screw Couplings on the JCB HM 1560Q

36

7.4

Tightening Torques for Screws and Screw Couplings on the JCB HM 1760Q

37

7.5

Tightening Torques for Screws and Screw Couplings on the JCB HM 2460Q

38

7.6

Tightening Torques for Screws and Screw Couplings on the JCB HM 3060Q and JCB HM 4160Q

39

7.7

Fitting the Cylinder

40

7.8

Fitting the Piston and sealing Bush

40

7.9

Fitting the Cylinder Cover

41

7.10

Fitting the Frequency Switching System

43

7.11

Fitting the Control Slide Valve

44

7.12

Fitting the Control System

44

7.13

Fitting the High-Pressure Accumulator

45

7.14

Checking Pressure in piston Accumulator and Refilling if Required

46

7.15

Fitting the Power Cell into the Hammer Housing

48

7.16

Connecting the JCB AUTOGREASE

49

7.17

Fitting the Tool

50

Assembling

Changing Seals 8

Changing the Seals

8.1

Changing the Cylinder Seals

51

8.2

Changing the Seals between Cylinder and Cylinder Cover

53

8.3

Changing the Seals on the Control System

53

8.4

Changing the Seals on the High Pressure Accumulator

54

8.5

Changing the seals on the Sealing Bush

54

9

Repair Work

55

9.1

Changing the Expansion Bolts on the High-Pressure Accumulator

55

9.2

Changing the High-Pressure Accumulator

55

9.3

Changing the Tie Rods

56

9.4

Removing Scores from Control slide Valve and Bore

57

51

Repair Work

9.5

Removing Scores on Piston and Cylinder Bore

57

9.6

Changing the Wear Bushes

58

9.7

Replacing the Complete Housing

60

ii

9803/1420-04

ii

Large Breakers - Contents Chapter

Title

Page

9.8

Replacing Guide Plates and Damping Elements in Housing

60

9.9

Repairing Cracked Welds

61

9.10

Replacing the Bottom Plate on the Housing

61

9.11

Reworking the Retainer Pins for the Damping Elements

62

9.12

Weld Seam Preparation

62

9.13

Preheating Temperature

62

9.14

Fillers

62

9.15

Post-treatment of Welds

62

10

Spares List

63

10.1

Percussion Unit

63

10.2

Noise Damping

64

10.3

JCB AUTOGREASE

65

1

Breaker Operating Principles

67

2

JCB Autogrease Operating Principles

75

Spares List

Appendices

Nitrogen Adaptor Reference Chart 11

Nitrogen Adaptor Reference Chart

90

Tool Part Numbers 12

Tool Part Numbers

92

Breaker Part Number Matrix 13

iii

Breaker Part Number Matrix

93

9803/1420-04

iii

Large Breakers - Contents

Page left intentionally blank

iv

9803/1420-04

iv

Large Breakers - Introduction

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9803/1420-04

1

Large Breakers - Safety

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9803/1420-04

2

Large Breakers - Safety 2.3 Safety Notices

DANGER

All mechanical equipment can be hazardous if operated without care or correct maintenance.

In this manual you will find warning messages. Read them. Understand them. They tell you of hazards and how to avoid them. If you do not understand the messages, ask your employer or local JCB Distributor.

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

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

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

If you are unsure of anything, about the machine or the job, ask someone who knows. Donâ&#x20AC;&#x2122;t assume anything - check it out.

Lightning Lightning can kill you. Do not use the equipment if there is lightning in your area.

A-1-3-5

WARNING Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.

INT-1-3-4

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

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

A-1-4-1

Remember

WARNING

BE CAREFUL BE ALERT BE SAFE

Now read the rest of this section before moving on to the rest of the manual.

B-1-1-2/1

Each safety notice starts with a signal word.

The meanings of the signal words are given below.

DANGER 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

WARNING Denotes a hazard exists.

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

INT-1-2-2

CAUTION 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.

The accumulator(s) in the Breaker 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.

WARNING 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 Breaker while it is installed on the carrier, disconnect the carrier alternator and battery. Note that electric welding of the Breaker tools will render them useless and make the warranty void.

B-1-3-2/1

WARNING Protect your ears. Working with the Breaker without wearing earmuffs can damage your hearing. Wear earmuffs when working with the hammer. Earplugs may be used as an alternative to earmuffs.

B-2-1-11

INT-1-2-3

3

9803/1420-04

3

Large Breakers - Safety ! CAUTION

! WARNING

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.

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.

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

8-4-1-3

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.

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

! WARNING After the Breaker has been stopped there may be pressure trapped inside it. This pressure could cause the Breaker to ‘fire’ unexpectedly and injure you.

Before working on the Breaker, take the following precautions: a

Do not stand in front of the tool.

b

Relieve external system pressure by operating the relevant controls.

c

Wait at least 10 minutes, to allow internal pressure to decay, before working on the Breaker.

INT-3-1-3

! WARNING

! CAUTION If you have an attachment which is not covered in this handbook do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.

5-5-1-1

Read this book carefully before operating the Breaker for the first time. Protect yourself and others against flying debris. Wear protective eye glasses and ear plugs when operating the Breaker. Stop the carrier engine before changing the tool or servicing the Breaker.

! CAUTION Take care when lifting/handling. Refer SPECIFICATION for the attachment weight.

to

B-2-1-2/2

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

! WARNING

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

Do not operate the equipment outside its limits.

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.

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

A-1-4-2

! WARNING 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.

2-2-6-5

4

9803/1420-04

4

Large Breakers - Tools

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9803/1420-04

5

Large Breakers - Tools

3.2 Service box The tools required for service work on the breaker JCB Large Breakers are contained in the Service box.

Service toolbox and contents can be ordered from JCB Service.

Item Qty.

Designation

JCB Part No. See List page 91/92.

1

1

Adapter for Nitrogen cylinder

2

1

Filler valve

892/01216

3

1

Test pressure gauge

892/01217

4

1

Hose

892/01218

5

1

Pin punch d = 9.5

5

1

Pin punch d = 15.5 L=130

6

1

Allen key

7

1

8

1

Hexagonal head bolt M 12 x 150 Hexagonal head bolt M 20 x 160

See Note See Note

Note: The choice of item 7 or 8 is dependant on the size of breaker.

Fig. 1 Service tools

6

9803/1420-04

6

Large Breakers - Tools

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9803/1420-04

9

Large Breakers - Tools

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10

9803/1420-04

10

Large Breakers - Technical Specifications

4

Technical Specifications

4.1 Breaker Specifications Model Service weight*

JCB HM 860Q 850 kg (1875 lb)

JCB HM 1260Q 1250 kg (2756 lb)

Serial No. from

1095001 on

1095001 on

Recommended carrier class

12 - 18 t (26460 - 39683 lb)

14 - 22 t (30870 - 48510 lb)

Impact rate

420 - 750 blows/min

350 - 600 blows/min

Impact energy (calculated)

1781 Joules

2404 Joules

Dimensions (excluding tool) Length Width Depth

1366 mm (54 in) 410 mm (16 in) 560 mm (22 in)

1579 mm (62 in) 495 mm (19.5 in) 630 mm (25 in)

Oil flow rate

80 - 110 l/min (18 - 24 UK gal/min) (22 - 29 US gal/min)

90 - 120 l/min (20 - 27 UK gal/min) (24 - 33 US gal/min)

Operating pressure

140 - 170 bar (2030 - 2465 psi)

140 - 170 bar (2030 - 2465 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

210 bar (2045 psi)

210 bar (2045 psi)

Maximum return line pressure

12 bar (174 psi)

12 bar (174 psi)

Tool diameter

100 mm (3.94 in)

115 mm (4.53 in)

Piston accumulator** Minimum gas pressure Required gas pressure

11 bar (159.5 psi) 13.5 bar (195.75 psi)

5.2 bar (75.4 psi) 7 bar (101.5 psi)

Sound pressure level measured r - 10 m (32.8 ft) 92 LP dB (A)

90 LP dB (A)

Sound power level*** guaranteed

121 LWA dB (A)

120 LWA dB (A)

BSP 3/4”

BSP 1”

Connecting thread on ports »P« and »T«

* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket. ** Depending on the oil flow rate. *** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool. **** Measuring process based on directive 2000/14/EC

11

9803/1420-04

11

Large Breakers - Technical Specifications

4.1 Breaker Specifications (continued)

Model

JCB HM 1560Q

Service weight*

1600 kg (3527 lb)

Serial No. from

1095001 on

Recommended carrier class

18 - 34 t (39683 - 74957 lb)

Impact rate

360 - 540 blows/min

Impact energy (calculated)

2781 Joules

Dimensions (excluding tool) Length Width Depth

1664 mm (65.6 in) 495 mm (19.5 in) 648 mm (25.5 in)

Oil flow rate

130 - 170 l/min (28.6 - 37.4 UK gal/min) (34 - 45 US gal/min)

Operating pressure

120 - 140 bar (1740 - 2030 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

210 bar (3045 psi)

Maximum return line pressure

12 bar (174 psi)

Tool diameter

135 mm (5.32 in)

Piston accumulator** Minimum gas pressure Required gas pressure

5.3 bar (76.85 psi) 8.2 bar (118.9 psi)

Sound pressure level measured r - 10 m (32.8 ft)

87 LP dB (A)

Sound power level*** guaranteed

117 LWA dB (A)

Connecting thread on ports »P« and »T«

BSP 1 1/4” DIN 2999

* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket. ** Depending on the oil flow rate. *** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool. **** Measuring process based on directive 2000/14/EC

12

9803/1420-04

12

Large Breakers - Technical Specifications 4.1 Breaker Specifications (continued)

Model Service weight*

JCB HM 1760Q 1700 kg (3748.5 lb)

Serial No. from

1095001 on

Recommended carrier class

18 - 34t (39683 - 74957 lb)

Impact rate

320 - 600 blows/min

Impact energy (calculated)

4022 Joules

Dimensions (excluding tool) Length Width Depth

1827 mm (72 in) 495 mm (19.5 in) 655 mm (25.8 in)

Oil flow rate

130 - 160 l/min (28.6 - 35.2 UK gal/min) (34 - 42 US gal/min)

Operating pressure

160 - 180 bar (2320 - 2610 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

210 bar (3045 psi)

Maximum return line pressure

12 bar (174 psi)

Tool diameter

140 mm (5.5 in)

Piston accumulator** Minimum gas pressure Required gas pressure

9.5 bar (137.75 psi) 12.3 bar (178.35 psi)

Sound pressure level measured r - 10 m (32.8 ft)

87 LP dB (A)

Sound power level*** guaranteed

117 LWA dB (A)

Connecting thread on ports »P« and »T«

Flange SAE 1 1/4” -6000 psi

* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket. ** Depending on the oil flow rate. *** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool. **** Measuring process based on directive 2000/14/EC

13

9803/1420-04

13

Large Breakers - Technical Specifications

4.1 Breaker Specifications (continued)

Model Service weight*

JCB HM 2460Q 2150 kg (4741 lb)

JCB HM 3060Q 3000 kg (6615 lb)

Serial No. from

1095001 on

1095001 on

Recommended carrier class

26 - 40 t (57330 -88200 lb)

32 - 50 t (70560 - 110250 lb)

Impact rate

280 - 550 blows/min

280 - 540 blows/min

Impact energy (calculated)

5400 Joules

7425 Joules

Dimensions (excluding tool) Length Width Depth

1946 mm (77 in) 650 mm (25.6 in) 700 mm (27.6 in)

2205 mm (87 in) 670 mm (26.4 in) 800 mm (31.5 in)

Oil flow rate

140 - 180 l/min (31 - 40 UK gal/min) (37 - 48 US gal/min)

210 - 270 l/min (46 - 60 UK gal/min) (55 - 72 US gal/min)

Operating pressure

160 - 180 bar (2320 - 2610 psi)

160 - 180 bar (2320 - 2610 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

210 bar (3045 psi)

210 bar (3045 psi)

Maximum return line pressure

12 bar (174 psi)

12 bar (174 psi)

Tool diameter

150 mm (6.0 in)

165 mm (6.5 in)

Piston accumulator** Minimum gas pressure Required gas pressure

12 bar (174 psi) 15.5 bar (225 psi)

12.5 bar (182 psi) 16 bar (232 psi)

Sound pressure level measured r - 10 m (32.8 ft) 91 LP dB (A)

93 LP dB (A)

Sound power level*** guaranteed

121 LWA dB (A)

122 LWA dB (A)

Flange SAE 1 1/4” -6000 psi

1 5/8”-12 UNF with JIC cone 37 deg.

Connecting thread on ports »P« and »T«

* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket. ** Depending on the oil flow rate. *** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool. **** Measuring process based on directive 2000/14/EC

14

9803/1420-04

14

Large Breakers - Technical Specifications

4.1 Breaker Specifications (continued)

Model Service weight*

JCB HM 4160Q 4120 kg (9085 lb)

Serial No. from

1095001 on

Recommended carrier class

42 - 75t (92610 - 165375 lb)

Impact rate

270 - 530 blows/min

Impact energy (calculated)

9167 Joules

Dimensions (excluding tool) Length Width Depth

2359 mm (93 in) 670 mm (26.4 in) 800 mm (31.5 in)

Oil flow rate

250 - 320 l/min (55 - 71 UK gal/min) (66 - 85 UK gal/min)

Operating pressure

160 - 180 bar (2320 - 2610 psi)

Static pressure (to be set on A.R.V. for breaker circuit)

210 bar (3045 psi)

Maximum return line pressure

12 bar (174 psi)

Tool diameter

180 mm (7.1 in)

Piston accumulator** Minimum gas pressure Required gas pressure

8.6 bar (125 psi) 11.5 bar (167 psi)

Sound pressure level measured r - 10 m (32.8 ft)

92 LP dB (A)

Sound power level*** guaranteed

122 LWA dB (A)

Connecting thread on ports »P« and »T«

1 5/8-12UNF” with JIC cone 37 deg.

* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket. ** Depending on the oil flow rate. *** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool. **** Measuring process based on directive 2000/14/EC

15

9803/1420-04

15

Large Breakers - Technical Specifications 4.2 Working Pressure/Required Flow/Engine RPM JS110 Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1599 1487 1589 1476 1567 1466 1546 1450 1530 1434 70

***** *****

1776 1653 1765 1647 1738 1637 1717 1621 1706 1605

1963 1851 1952 1845 1937 1835 1915 1819 1899 1803

2199 2086 2188 2081 2172 2070 2150 2054 2129 2038

2300 2210

80 90 100 Required Flow (l/min)

110

Upper figure = No load pressure Lower figure = Loaded engine pressure

JS130 Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1495 1390 1485 1380 1465 1370 1445 1355 1430 1340 70

***** *****

16

1660 1545 1650 1540 1625 1530 1605 1515 1595 1500

1835 1730 1825 1725 1810 1715 1790 1700 1775 1685

2055 1950 2045 1945 2030 1935 2010 1920 1990 1905

2205 2110 2190 2100 2170 2080 2150 2065

2250 2115

80 90 100 Required Flow (l/min)

110

115

Upper figure = No load pressure Lower figure = Loaded engine pressure

9803/1420-04

16

Large Breakers - Technical Specifications 4.2 Working Pressure/Required Flow/Engine RPM (continued) JZ140 Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1495 1390 1485 1380 1465 1370 1445 1355 1430 1340 70

***** *****

1660 1545 1650 1540 1625 1530 1605 1515 1595 1500

1835 1730 1825 1725 1810 1715 1790 1700 1775 1685

2055 1950 2045 1945 2030 1935 2010 1920 1990 1905

2205 2110 2190 2100 2170 2080 2150 2065

2250 2115

80 90 100 Required Flow (l/min)

110

115

2140 2045 2130 2035 2115 2025 2100 2020 2080 2005

2320 2210 2310 2215 2295 2205 2280 2195 2265 2170

2360 2265

90 100 110 Required Flow (l/min)

120

125

Upper figure = No load pressure Lower figure = Loaded engine pressure

JS160/JS180 Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1590 1480 1575 1470 1560 1460 1540 1445 1525 1430 80

***** *****

17

1765 1660 1750 1655 1735 1645 1720 1630 1700 1615

1985 1875 1970 1870 1955 1860 1940 1850 1920 1840

Upper figure = No load pressure Lower figure = Loaded engine pressure

9803/1420-04

17

Large Breakers - Technical Specifications 4.2 Working Pressure/Required Flow/Engine RPM (continued) JS200/JS220 Working Pressure (bar) 220 200 180 160 140 120 100 80

***** *****

Engine Speed (rpm) 1345 1210 1320 1200 1290 1185 1255 1165 1135 1020 1075 970 1015 9155 955 860

1380 1255 1340 1210 1330 1200 1300 1190 1255 1155 1190 1090 1135 1040 1070 975

1505 1385 1410 1290 1335 1220 1320 1205 1305 1200 1290 1180 1250 1160 1195 1100

1635 1525 1535 1415 1455 1345 1390 1280 1340 1235 1300 1200 1295 1200 1280 1200

1765 1660 1650 1545 1555 1450 1490 1390 1440 1340 1400 1305 1370 1285 1365 1280

1905 1805 1780 1680 1690 1595 1595 1505 1540 1445 1490 1405 1470 1390 1460 1385

2065 1985 1925 1830 1805 1710 1725 1635 1650 1560 1590 1510 1560 1480 1560 1490

2040 1960 1930 1845 1835 1750 1765 1680 1690 1610 1670 1595 1660 1595

80

90

100

110

120

130 140 150 Required Flow (l/min)

2055 1925 1965 1880 1880 1800 1800 1720 1775 1705 1765 1700

2095 2015 1985 1905 1905 1830 1870 2800 1860 1800

2095 2025 2015 1950 1965 1900 1955 1900

2055 2000 2040 1990

160

170

180

190

1965 1785 1870 1695 1825 1645 1790 1640 1750 1625 1710 1610 1680 1605

2075 1900 1990 1815 2005 1840 1880 1740 1850 1725 1810 1720 1785 1710

2005 1840 1975 1830 1935 1815 1920 1815 1885 1800

2075 1935 2040 1920 2010 1905 1970 1890

160

170

180

190

Upper figure = No load pressure Lower figure = Loaded engine pressure

JS240/JS260 Working Pressure (bar) 220 200 180 160 140 120 100 80

***** *****

18

Engine Speed (rpm) 1360 1170 1275 1082 1180 985 1040 880 1130 870 980 840 935 820 910 825

1415 1190 1385 1180 1320 1140 1230 1045 1145 990 1085 955 1030 920 1010 920

1435 1205 1415 1200 1375 1185 1310 1160 1250 1110 1185 1060 1120 1030 1100 1025

1500 1275 1425 1205 1410 1210 1380 1200 1340 1195 1295 1175 1235 1130 1195 1125

1620 1400 1535 1320 1450 1265 1445 1250 1395 1240 1360 1230 1310 1220 1285 1215

1720 1520 1645 1440 1560 1370 1530 1335 1495 1340 1460 1330 1420 1320 1370 1300

1830 1640 1750 1555 1670 1480 1640 1450 1605 1445 1550 1425 1525 1425 1475 1405

1950 1765 18500 1670 1770 1585 1730 1550 1700 1545 1660 1525 1620 1520 1590 1510

80

90

100

110

120

130 140 150 Required Flow (l/min)

Upper figure = No load pressure Lower figure = Loaded engine pressure

9803/1420-04

18

Large Breakers - Technical Specifications 4.2 Working Pressure/Required Flow/Engine RPM (continued) JS130W/JS145W Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1495 1390 1485 1380 1465 1370 1445 1355 1430 1340

1660 1545 1650 1540 1625 1530 1605 1515 1595 1500

1835 1730 1825 1725 1810 1715 1790 1700 1775 1685

2055 1950 2045 1945 2030 1935 2010 1920 1990 1905

2205 2110 2190 2100 2170 2080 2150 2065

2250 2115

70

80

90

100

110

115

Required Flow (l/min) ***** *****

Upper figure = No load pressure Lower figure = Loaded engine pressure

JS160W/JS175W Working Pressure (bar) 150 140 130 120 110

Engine Speed (rpm) 1590 1480 1575 1470 1560 1460 1540 1445 1525 1430

1765 1660 1750 1655 1735 1645 1720 1630 1700 1615

80

90

1985 1875 1970 1870 1955 1860 1940 1850 1920 1840

2140 2045 2130 2035 2115 2025 2100 2020 2080 2005

2320 2210 2310 2215 2295 2205 2280 2195 2265 2170

2360 2265

100

110

120

125

Required Flow (l/min) ***** *****

19

Upper figure = No load pressure Lower figure = Loaded engine pressure

9803/1420-04

19

Large Breakers - Technical Specifications 4.2 Working Pressure/Required Flow/Engine RPM (continued)

JS200W The hydraulic flow to the breaker on a JS200W machine is controlled by adjusting the servo pressure onto the end of the hammer spool in the control valve. Refer to the machine service manual for the position of the hammer spool.

20

9803/1420-04

20

Large Breakers - Dismantling

$ISMANTLING THE (YDRAULIC "REAKER

&ITTING 2EMOVING THE 4OOL )N GENERAL THE TOOL IS NOT FITTED WHEN THE BREAKER IS DELIVERED &OR FITTING MOVE THE BREAKER INTO HORIZONTAL POSITION USING THE EXCAVATOR BOOM AND DEPOSIT IT ON A SUPPORT E G SQUARED BEAMS &OR SAFETY REASONS THE CARRIER MUST BE SWITCHED OFF BEFORE PERFORMING THE FOLLOWING WORK

2EMOVE THE RETAINER BARS BY TURNING A SCREW INTO THE - THREAD PROVIDED AND USING THE SCREW TO PULL OUT THE BAR 2EMOVE THE DUST CAP FROM THE TOOL BORE AND PUT IT IN THE TOOLBOX FOR SAFEKEEPING

#!54)/.

#LEAN AWAY ANY DIRT ADHERING TO THE TOOL IN THE INSERTION ZONE THEN THOROUGHLY LUBRICATE THE SHAFT OF THE TOOL AND THE BUSHES WITH *#" !54/'2%!3%

!LWAYS WEAR PROTECTIVE GLASSES WHEN FITTING OR REMOVING THE TOOL SINCE METAL SPLINTERS MAY FLY OFF WHEN HAMMERING OUT THE LOCKING PINS

4HE RETAINER BARS ARE ALSO TO BE LUBRICATED

4O GAIN ACCESS TO THE LOCKING PINS REMOVE THE FOUR SEALING PLUGS ! FITTED IN THE SIDES OF THE HOUSING +NOCK THE LOCKING PINS " OUT OF THE LOWER BREAKER SECTION USING THE DRIFT CONTAINED IN THE TOOLBOX .OTE THAT THE LOCKING PINS CAN ONLY BE BE REMOVED IN ONE DIRECTION 8 4O GAIN ACCESS TO THE THE TOOL RETAINER BARS $

REMOVE THE TWO UPPER SEALING PLUGS # FROM THE BREAKER HOUSING AND THE TWO INNER SEALING PLUGS % FROM THE POWERCELL

#!54)/. .EVER USE YOUR FINGERS TO CHECK THE ALIGNMENT OF THE RECESSES IN THE WORKING TOOL TO THE OBLONG HOLES FOR THE RETAINING BARS 4HEN INSERT THE TOOL TURNING IT UNTIL THE RETAINER BARS SLIDE EASILY INTO THE SLOTS 2EPLACE THE SEALING PLUGS AND DRIVE THE LOCKING PINS FOR THE RETAINER BARS BACK INTO POSITION

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Large Breakers - Assembling

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9803/1420-04

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Large Breakers - Assembling

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9803/1420-04

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Large Breakers - Assembling #HECKING 0RESSURE IN 0ISTON !CCUMULATOR AND 2EFILLING IF 2EQUIRED 4HESE ITEMS SHOULD BE ON HAND AT ALL TIMES TO ALLOW THE FOLLOWING CHECKING AND MAINTENANCE WORK TO BE PERFORMED

&ILLING REFILLING

NITROGEN FILLING DEVICE PRESSURE GAUGE IN BAR TEST CLASS NITROGEN CYLINDER 0ARTS .OS #OMPLETE KIT AND

0REPARATIONS

!LL TOOLS AND PARTS REQUIRED FOR FILLING ARE CONTAINED IN THE TOOLBOX #ONNECT THE PRESSURE RELIEF VALVE TO THE NITROGEN CYLINDER #ONNECT ONE NOZZLE OF THE FILLING HOSE TO THE -INI MESS PORT ON THE PRESSURE RELIEF VALVE

#HECKING )F THE PERFORMANCE OF THE HYDRAULIC BREAKER STARTS TO DROP THE GAS PRESSURE IN THE BREAKER S PISTON ACCUMULATOR SHOULD BE CHECKED 4HE PISTON ACCUMULATOR DOES NOT NEED TO BE REFILLED UNTIL THE GAS PRESSURE HAS DROPPED TO THE MINIMUM LEVEL OR BELOW

#LOSE THE PRESSURE RELIEF VALVE /PEN THE VALVE ON THE NITROGEN CYLINDER 5NSCREW THE PLUG FROM FILLING VALVE w'i 0RESS THE FREE NOZZLE ON THE FILLING HOSE INTO THE FILLING VALVE w'i

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46

-INIMUM 'AS PRESSURE

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9803/1420-04

46

Large Breakers - Assembling #HECKING AND LOWERING PRESSURE 2EMOVE THE FILLING HOSE FROM THE PRESSURE RELIEF VALVE AND CONNECT IT TO THE PRESSURE GAUGE 0RESS THE FREE NOZZLE OF THE FILLING HOSE BACK INTO FILLING VALVE w'i AND READ OFF THE PRESSURE 4HE PRESSURE IN THE PISTON ACCUMULATOR CAN BE LOWERED TO THE REQUIRED READING BY REPEATEDLY PUSHING IN AND PULLING OUT THE HOSE NOZZLE !FTER FILLING

5SE ONLY NITROGEN FROM THE GREEN GAS CYLINDER TO FILL THE PISTON ACCUMULATOR .EVER USE ANY OTHER GAS E G AIR OR OXYGEN $!.'%2 RISK OF EXPLOSION 7HEN FILLING THE PISTON ACCUMULATOR ENSURE NO ONE IS IN THE VICINITY OF THE WORKING TOOL )F THE TOOL HAS JAMMED THE INCREASE IN PRESSURE IN THE PISTON ACCUMULATOR MAY CAUSE IT TO SPRING OUT SUDDENLY

3CREW THE PLUG BACK ONTO FILLING VALVE w'i TO CLOSE IT #LOSE THE VALVE ON THE NITROGEN CYLINDER /PEN THE PRESSURE RELIEF VALVE FULLY TO ALLOW ANY RESIDUAL GAS TO ESCAPE 2EMOVE THE PRESSURE RELIEF VALVE #!54)/. /NLY USE THE HOSE NOZZLE TO RELIEVE THE PRESSURE .EVER USE NAILS SCREWDRIVERS OR SIMILAR OBJECTS FOR THIS PURPOSE AS THEY WILL DAMAGE THE FILLING VALVE

$!.'%2 RISK OF INJURY "EFORE REMOVING THE COMPLETE FILLING VALVE w'i THE PISTON ACCUMULATOR MUST BE COMPLETELY DEPRESSURISED 4O THIS END UNSCREW THE VALVE PLUG AND DEPRESS THE VALVE PISTON IN THE FILLING VALVE USING THE NOZZLE OF THE FILLING HOSE 4HIS WILL ALLOW THE NITROGEN TO ESCAPE SAFELY FROM THE CYLINDER COVER OF THE HYDRAULIC BREAKER

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9803/1420-04

47

Large Breakers - Assembling

7.15 Fitting the power cell into the hammer housing v

Stand the housing ( Fig. 49/1) upright.

v

Replace any defective damping elements (Fig. 49/2), guide plates (Fig. 49/3) (see 6).

v

Fit plastic elements and fix in position using double-sided adhesive tape; if wear is detected, insert shims. (Service openings must remain accessible).

v

Lift the power cell using a crane/hoist and lower into housing.

v

Lower the power cell into hammer housing using a crane/hoist.

DANGER! Never use your hands to locate or check the position of the plastic elements or the shims when fitting the power cell.

v

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v

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v

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DANGER! Only use the original allen screws to fasten the adapter. v

48

The Allen screws must be tightened to the required torque. (Tightening torque, see 7.1 to 7.6).

- 400 Nm for M20 - 1500 Nm for M30 - 1800 Nm for M36

Fig. 49

9803/1420-04

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Large Breakers - Assembling

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Large Breakers - Changing Seals

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Large Breakers - Spares List 6SDUHV /LVW 1RLVH 'DPSLQJ

8

$ETA IL

!TTACHMENT TO AN EXISTING CARRIER REQUIRES AN ADDITIONAL HANGER BRACKET MATCHING THE CARRIER IN QUESTION

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Large Breakers - Spares List

6SDUH OLVW -&% $872*5($6(

0ARTS

AND SECURED BY ,OCTITE )MPORTANT 4HE HOSES PARTS AND MUST BE LAID IN ACCORDANCE WITH THE DIAGRAM ENSURING THAT THEY CAN BE MOVED FREELY AND DO NOT MAKE CONTACT AT ANY POINT

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Large Breakers - Spares List

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Large Breakers - Appendix 1

Breaker Operating Principles Breaker Piston

AG

A1

A1 > A 2

A2

Control Area

A = Ring Impact Area

area

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Large Breakers - Appendix 1 Breaker Operating Principles Control Valve

Control Valve

A

1 A

A

A

1

1

> A

< A

2

2

+A

ST

ST A = Ring area

A

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Large Breakers - Appendix 1 Breaker Operating Principles Stage 1 - Start Up

Stage 1 - Start Up

X Ta n k Pum p

Pi l o t l i n e

Ta n k

Up p e r o i l cham ber

Pu m p

At initial start up, oil enters the breaker and the pressure rises. At this point the control valve is in the upper position. As the pressure rises, the cavity at the top of the valve also becomes pressurised through a pilot drilling through the centre of the valve spool (X).

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Large Breakers - Appendix 1 Breaker Operating Principles Stage 2 - Return Stroke

Stage 2 - Return Stroke

Tank Pump

Pilot line

Tank

Upper oil Pump

chamber

The hydraulic force generated by the larger surface area at the top of the valve causes the spool to be pushed downwards, releasing the oil from the top of the piston and the pilot line into the tank line.

The high pressure oil acting on the lower piston now causes the piston to rise in the cylinder.

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Large Breakers - Appendix 1 Breaker Operating Principles Stage 3 - End of Return and Power Stroke

Stage 3 - End of Return and Power Stroke

Tank Pump

Pilot line

Tank

Upper oil Pump

chamber

When the piston reaches the top of its stroke, high pressure oil is released to the control spool via the pilot line, raising the valve spool and allowing the incoming high pressure oil to now act on the top section on the piston. This prevents any further upward movement of the piston. The larger surface area of the top section of the piston now generates a greater hydraulic force than the lower area and the piston is driven downwards.

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Large Breakers - Appendix 1 Breaker Operating Principles Stage 4 - Power Stroke Continued

Stage 4 - Power Stroke Continued

Tank Pump

Pilot line

Tank

Upper oil Pump

chamber

When the piston impacts on the tool, the pilot line is connected to tank via the control area of the piston.

This in turn allows the control valve spool to move and exhaust the upper piston area to tank. The pressurised oil now acting on the lower piston area now starts to raise the piston and commences a new cycle.

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Large Breakers - Appendix 1 Breaker Operating Principles Operation of Hydraulic Brake

Operation of Hydraulic Brake

Tank Pump

Pilot line

Tank

Upper oil chamber

Pump

(X)

If no ground pressure is being applied to the tool, the piston continues its downward motion allowing high pressure oil into the pilot line via the control area of the piston and the lower shoulder of the piston now enters the hydraulic brake (X). This prevents damaging contact between the piston and the buffer ring and also prevents further operation of the breaker until ground pressure is re-established on the tool and the piston is lifted out of the hydraulic brake.

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Large Breakers - Appendix 1 Breaker Operating Principles Operation of Hydraulic Brake

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Large Breakers - Appendix 2

JCB Autogrease Operating Principles Features – Compact self-priming grease pumping unit.

– Unit mounted directly on the breaker housing.

– Greasing unit hoses protected inside the breaker housing.

– System operated by the breaker’s internal hydraulic system.

– No tools required to exchange the grease

cartridge ( Screw fit ).

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Large Breakers - Appendix 2 Typical Installation

*UHDVH 3XPS

'HOLYHU\ +RVH

*UHDVH &DUWULGJH

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3UHVVXUH +RVH

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation \ M

6PDOO 6PDOO 'HOLYHU\ 3LVWRQ

/RFN 1XW /DUJH 'HOLYHU\ 3LVWRQ 6HW 'HOLYHU\

&DUWULGJH 6HDO 6HOI &XWWLQJ 7KUHDG &DUWULGJH 3LVWRQ

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*UHDVH &DUWULGJH

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation

Lock Nut

Adjusting Screw

1

Unscrew locknut.

2

Counter clockwise: Delivery increasing.

3

Clockwise: Delivery decreasing.

4

Tighten locknut

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation

Minimum Adjusted Pump Delivery

1

Loosen locknut.

2

Screw adjuster in fully and then unscrew by 2 turns.

3

Retighten locknut.

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation

Maximum Adjusted Pump Delivery

1

Loosen locknut.

2

Unscrew adjuster until bottom of locknut threads are level with pump body.

3

Tighten locknut.

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation

Installation Schematic â&#x20AC;&#x201C; Breaker not Operating

Lubrication port

Hydraulic power source

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Typical Installation

Installation Schematic â&#x20AC;&#x201C; Breaker Operating

Lubrication port

Hydraulic power source

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 1

Stage 1

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 2

Stage 2

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 3

Stage 3

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 4

Stage 4

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 5

Stage 5

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 6

Stage 6

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Large Breakers - Appendix 2 JCB Autogrease Operating Principles Stage 7

Stage 7

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Large Breakers - Nitrogen Adaptor Reference Chart

Country

Adaptor

Part No

Algeria Argentina Armenia Australia Austria Azerbaijan Bahamas Bahrain Bangladesh Barbados Belgium Bolivia Botswana Brazil Bulgaria Burma Canada Chile China Colombia Costa Rica Czech Republic Denmark Djibouti Dom. Republic Ecuador Egypt Ethiopia Fiji Finland France Gabon Gambia Georgia Germany Ghana Greece Guatemala Guinea Guyana Honduras Hongkong Hungary India Indonesia Iran Iraq Ireland Israel Italy Ivory Coast Jamaica Japan Jordan Jugoslavia Kazakhstan Kenya Korea

40h 40b 40n 40b Direct.*** 40n 40b 40h 40b 40b Direct*** 40g 40b 40g 40n 40b 40c 40g 40k 40g 40b Direct*** Direct*** 40h 40g 40g 40b 40b 40b Direct*** 40h 40h 40b 40n Direct*** 40b 40h 40g 40h 40g 40g 40b 40h 40b 40b 40h 40h 40b 40h 40d 40h 40b 40e 40h 40h 40n 40b 40f

892/01202 892/01196 892/01207 892/01196 892/01207 892/01196 892/01202 892/01196 892/01196 892/01201 892/01196 892/01201 892/01207 892/01196 892/01197 892/01201 892/01204 892/01201 892/01196

892/01202 892/01201 892/01201 892/01196 892/01196 892/01196 892/01202 892/01202 892/01196 892/01207 892/01196 892/01202 892/01201 892/01202 892/01201 892/01201 892/01196 892/01202 892/01196 892/01196 892/01202 892/01202 892/01196 892/01202 892/01198 892/01202 892/01196 892/01199 892/01202 892/01202 892/01207 892/01196 892/01200

Country

Adaptor

Part No

Kuwait Kyrgyzstan Lebanon Libya Lichtenstein Luxembourg Malawi Malaysia Malta Mauritius Mexico Moldova Morocco Mozambique Netherlands New Zealand Nigeria Norway Oman Pakistan Paraguay Peru Philippines Poland Portugal Puerto Rico Qatar Romania Russ. Feder.

Saudi-Arabia Singapore Slovakia Slovenia South Africa Spain Sri Lanka Sudan Surinam Swaziland Sweden Switzerland Syria Taiwan Tanzania Thailand Trinidad/Tobago Tunisia Turkey Turkmenistan Ukraine United Arab Emirates Great Britain Uruguay USA Uzbekistan Venezuela Vietnam Zambia

40h 40n 40h 40h Direct*** Direct*** 40b 40l 40b 40h 40h 40n 40h 40h Direct*** 40b 40h Direct*** 40h 40b 40g 40g 40b Direct*** 40b 40c 40k 40h 40n 40h 40b Direct*** Direct*** 40b 40h 40b 40b 40b 40b Direct*** Direct*** 40h 40b 40b 40b 40m 40h 40b 40n Direct*** 40h 40b 40g 40c 40n 40n 40b 40b

892/01202 892/01207 892/01202 892/01202

892/01196 892/01205 892/01196 892/01202 892/01202 892/01207 892/01202 892/01202 892/01196 892/01202 892/01202 892/01196 892/01201 892/01201 892/01196 892/01196 892/01197 892/01204 892/01202 892/01207 892/01202 892/01196

892/01196 892/01202 892/01196 892/01196 892/01196 892/01196

892/01202 892/01196 892/01196 892/01196 892/01206 892/01202 892/01196 892/01207 892/01202 892/01196 892/01201 892/01197 892/01207 892/01207 892/01196 892/01196

Direct*** means the adaptor supplied with the Breaker is suitable for this territory.

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Large Breakers - Nitrogen Adaptor Reference Chart

892/01208 892/01208

892/01205

892/01205

892/01202 892/01202

892/01199 892/01199

892/01196 1196

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892/01206 892/01206

892/01207 892/01207

892/01203 892/01203

892/01204 892/01204

892/01200 892/01200

892/01197 892/01197

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892/01201 892/01201

892/01198 892/01198

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Large Breakers - Tool Part Numbers

Breaker Type HM860Q

HM1260Q

HM1560Q

HM1760Q

HM2460Q

HM3060Q

HM4160Q

Description Moil Point Flat chisel Chisel wide Moil Point Flat chisel Blunt tool Moil Point Flat chisel Blunt tool Moil Point Flat Chisel Blunt tool Moil Point Flat chisel Blunt tool Moil Point Flat chisel Blunt tool Moil Point Flat chisel Blunt tool

Diameter Overall Length Working Length mm ins. mm ins. mm ins.

100 3.94 1000 39.37 560 22.05 100 3.94 1000 39.37 560 22.05 100 3.94 950 37.4 510 20.08 115 4.53 1120 44.09 685 26.97 115 4.53 1120 44.09 685 26.97 115 4.53 1120 44.09 685 26.97 135 5.31 1140 44.88 625 24.61 135 5.31 1140 44.88 625 24.61 135 5.31 1140 44.88 625 24.61 140 5.51 1200 47.24 650 25.59 140 5.51 1200 47.24 650 25.59 140 5.51 1200 47.24 650 25.59 150 5.91 1150 45.28 500 19.69 150 5.91 1150 45.28 500 19.69 150 5.91 1150 45.28 500 19.69 165 6.5 1300 51.18 595 23.43 165 6.5 1300 51.18 595 23.43 165 6.5 1300 51.18 595 23.43 180 7.09 1400 55.12 620 24.41 180 7.09 1400 55.12 620 24.41 180 7.09 1400 55.12 620 24.41

Tip Width Part Number mm ins.

331/53613 100 3.94 331/53614 200 7.87 331/53618 331/53895 115 4.53 331/53896 331/53897 331/54339 331/54340 331/54341 331/54343 140 5.51 331/54344 331/54345 331/54347 150 5.91 331/54348 331/54349 331/54350 165 6.5 331/54351 331/54352 331/54354 180 7.09 331/54355 331/54356

Note: A standard Chisel or Asphalt Cutter is supplied with the cutting face perpendicular to the boom.

A Parallel Chisel or Asphalt cutter have the cutting face parallel with the boom.

A range of steels are available to meet all applications.

Manufactured from high quality materials for long life.

Use tool selection guide below.

MOIL - Universal - For layered rock and reinforced concrete, where twisting could occur.

PYRAMID POINT (All Moils above 100mm diameter)-.

CHISEL - Standard tool for penetrative work. e.g. Mining, foundations, trenching, demolition.

BLUNT - For impact breaking. e.g. Mining, breaking oversizes, demolition.

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Large Breakers - Breaker Part Number Matrix

Part No. 980/90213 980/90289 980/90215 980/90290 980/90216 980/90291 980/90247 980/90292 980/90218 980/90293 980/90219 980/90294 980/90220 980/90295 980/90221 980/90296 980/90222 980/90297 980/90223 980/90298 980/90224 980/90299 980/90225 980/90300 980/90264 980/90265 980/90266 980/90267 980/90268 980/90269 980/90270 980/90271 980/90272 980/90273 980/90274 980/90275 980/90276 980/90277

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Machine JS130,JZ140 JS130,JZ140 JS130,JZ140 JS130,JZ140 JS160,JS180 JS160,JS180 JS160,JS180 JS160,JS180 JS200,JS220 JS200,JS220 JS200,JS220 JS200,JS220 JS240,JS260 JS240,JS260 JS240,JS260 JS240,JS260 JS330 JS330 JS330 JS330 JS460 JS460 JS460 JS460

Universal Options

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DESCRIPTION HM860 with Moil HM860 with Chisel HM1260 with Moil HM1260 with Chisel HM1260 with Moil HM1260 with Chisel HM1560 with Moil HM1560 with Chisel HM1560 with Moil HM1560 with Chisel HM1760 with Moil HM1760 with Chisel HM1760 with Moil HM1760 with Chisel HM2460 with Moil HM2460 with Chisel HM2460 with Moil HM2460 with Chisel HM3060 with Moil HM3060 with Chisel HM3060 with Moil HM3060 with Chisel HM4160 with Moil HM4160 with Chisel HM860Universal with Moil HM860Universal with Chisel HM1260Universal with Moil HM1260Universal with Chisel HM1560Universal with Moil HM1560Universal with Chisel HM1760Universal with Moil HM1760Universal with Chisel HM2460Universal with Moil HM2460Universal with Chisel HM3060Universal with Moil HM3060Universal with Chisel HM4160Universal with Moil HM4160Universal with Chisel

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