JCB Hydraulic Breakers HM22, HM25, HM29, HM26 Service Manual - PDF DOWNLOAD

CONTENTS

INTRODUCTION Section A MAINTENANCE (HM 22, 25, 29) Section B MAINTENANCE (OTHERS) Section C SPECIFICATION - BREAKERS Section D HYDRAULIC POWERPACKS Section E SPECIFICATION - POWERPACKS Section F

! 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.

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Issue 3

A1

INTRODUCTION

A1

ABOUT THIS MANUAL

To ensure that the JCB series of hydraulic breakers can be operated efficiently and safely, they must be serviced and maintained regularly. This manual is designed to give you a good understanding of the breaker and provide detailed maintenance information.

It is assumed that personnel carrying out maintenance have at least a sound knowledge of workshop practice, safety procedures and general techniques associated with the repair of hydraulic equipment.

Details of such are, therefore, generally omitted from the manual, the intention being to convey only the more specialised information concerning particular aspects of the breaker or component in question.

For example, renewal of oil seals, 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.

BREAKER MODEL AND SERIAL NUMBER The following breakers are covered by this manual: 1 2 3 4 5 6 7 8

Standard handle breakers Vibro-damped handle breakers ‘D’ handle picks ‘T’ handle picks HM 22 HM 25 HM 29 HM 26 (Non EU)

The serial number of your breaker is stamped on the breaker as shown. It is important to quote the serial number when making repairs or ordering parts.

Identification of the serial number is the only means of ensuring that you receive the correct part for your particular breaker.

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

c

D

20LPM AT 138 BAR ETHMA CATEGORY

30LPM AT 138 BAR ETHMA CATEGORY

TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "C" POWERPACKS

TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "D" POWERPACKS

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The JCB series of hydraulic breakers are categorized by the EHTMA as Category ‘C’ or ‘D’ breakers and can be safely used on any hydraulic powerpack displaying the green EHTMA ‘C’ or ‘D’ decals as shown below.

Issue 2

A2

INTRODUCTION

A2

TORQUE SETTINGS

Only use the following torque settings when no setting is specified in the manual.

CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced with bolts of a lesser tensile specification.

TABLE OF IMPORTANT TIGHTENING TORQUES Tightening Points Nm

Tightening Torques kgf m

lbf ft

Capscrew Size

Top cover to head capscrews (Standard, 20 kg & 23 kg) Top cover to head capscrews (Standard, 26 kg)

135 215

13.8 21.9

100 158

M12 M14

Handle bracket to head capscrews (Vibro, 22 kg & 25 kg) Handle bracket to head capscrews (HM22 & HM25) Handle bracket to head capscrews (Vibro, 28 kg) Handle bracket to head capscrews (HM29)

135 135 215 215

13.8 13.8 21.9 21.9

100 100 158 158

M12 M12 M14 M14

67

6.8

50

Top cover to Handle bracket capscrews (Vibro, 22kg, 25kg & 28 kg) 16 Top cover to Handle bracket capscrews (HM22,HM25,HM29) 16

1.6 1.6

11.9 11.9

Handle to top cover capscrews (Standard, 20kg, 23kg & 26 kg)

Barrel to nose capscrews (Standard 20, 23 kg & Vibro 22, 25kg) Barrel to nose capscrews (HM22 & HM25) Barrel to nose capscrews (Standard 26 kg & Vibro 28 kg) Barrel to nose capscrews (HM29)

135 135 215 215

13.8 13.8 21.9 21.9

100 100 158 158

M12 M12 M14 M14

Head assy to barrel/nose assy (Standard 20 kg & Vibro 22 kg) Head assy to barrel/nose assy (HM22) Head assy to barrel/nose assy (Standard 26 kg & Vibro 28 kg) Head assy to barrel/nose assy (HM29)

135 135 215 215

13.8 13.8 21.9 21.9

100 100 158 158

M12 M12 M14 M14

80

8.1

59

M10

135

13.8

100

M12

Accumulator top to head capscrews (‘D’ & ‘T’) Barrel to head capscrews (‘D’ & ‘T’)

Note:Check breaker specification to match breaker weight with the model number of your breaker.(see Section D)

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A3

INTRODUCTION

A3

SAFETY DECALS

Decals on the breaker warn you of particular hazards.Read, and make sure you understand the safety message before you work with the breaker.

Keep all decals clean and readable. Replace lost or damaged decals. The 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.

50

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A4

A4

INTRODUCTION SAFETY FIRST - YOURS AND OTHER PEOPLE’S

All hydraulic equipment can be hazardous. When hydraulic equipment is correctly operated and properly maintained, they are safe machines to work with. But when correct operation and maintenance routines are not followed, the machines can be a danger to you (the operator) and others.

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

But safety is not just a matter of responding to the warnings.

All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

Do not work with the machines until you are sure that you can control them.

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. Do not assume anything.

Remember BE CAREFUL BE ALERT BE SAFE

SAFETY CHECK LIST GENERAL SAFETY ! WARNING

! WARNING

Handbook You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the instructions before operating the machine. If there is anything that you do not understand, ask your employer or JCB Dealer to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook readily available or if there is anything on the machine that you do not understand.

Clothing You can be injured if you do not wear correct clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: hard hat, safety shoes, safety glasses, a well fitting overall, ear protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

! WARNING

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

Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Renew unreadable and missing decals before operating the machine. Make sure replacement parts include warning decals where necessary.

OPERATING SAFETY

! WARNING

! WARNING Regulations Obey all laws, worksite and local regulations which affect you and your machine.

! WARNING

! WARNING

Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are complete before using the machine.

Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practicing them. Practice away from the worksite on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

! WARNING Hydraulic Tools Hydraulic tools can be dangerous. Observe all safety instructions relevant to the tool you will be operating. If in any doubt, consult you JCB Dealer.

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! WARNING Exhaust Gasses Breathing the machine exhaust gases can harm and possibly kill you. Do not operate in closed spaces without making sure there is good ventilation.

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A5

A5

INTRODUCTION SAFETY CHECK LIST (continued) ! WARNING

! WARNING

Communications Bad communications can cause accidents. Keep people around informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

Petrol Petrol is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

! WARNING

! WARNING

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in a closed area where there is flammable material, vapour or dust.

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

! WARNING Hot Surfaces Under normal working conditions the engine components, particularly the exhaust system, will get hot - DO NOT TOUCH. The hydraulic oil, pump, valve and tank can also reach temperatures high enough to burn - DO NOT TOUCH.

! WARNING Noise Excessive noise can be hazardous to your health. Always wear ear defenders when operating the machine.

MAINTENANCE SAFETY

! WARNING Fires Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioide, dry chemical or foam extinguishers. Contact your nearest Fire Department as quickly as possible. Firefighters should use self-contained breathing apparatus.

! WARNING Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers.

! WARNING Repairs Do not try to do repairs or any type of maintenance work which you do not fully understand, get the work done by a specialist engineer.

! WARNING Modifications Non-approved modifications can cause injury and damage.

Contract your JCB Dealer before modifying the machine.

! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

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B

B

MAINTENANCE CONTENTS

Lubricants - Health and Safety Hygiene Storage Handling First aid - Oil Fires Waste disposal

B1

Service Schedules Daily Monthly

B2

Breaker dismantling - HM22, 25, 29

B3

Breaker inspection - HM22, 25, 29

B6

Breaker assembly - HM22, 25, 29

B8

Charging the accumulator Equipment required Charging pressure Charging procedure

B11

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.

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MAINTENANCE

B1

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.

e Avoid skin contact with oil soaked clothing. f

Do not keep oily rags in pockets.

g Wash dirty clothing before reuse.

Hygiene h Throw away oil soaked shoes.

JCB lubricants are not a health risk when used properly for their intended purpose.

First Aid-Oil

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Low viscosity oils are more likely to do this, so take special care when handling used oils which may be diluted with fuel contamination.

Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists get medical attention.

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.

Skin In the case of excessive skin contact, wash with soap and water.

Storage Always keep lubricants out of reach of children. Never store lubricants in open or unlabelled containers.

Handling

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.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Waste Disposal All waste products should be disposed of in accordance with the relevant regulations.

Used Oil Used oils contain harmful contaminants. Here are pre cautions to protect your health when handling used oil.

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.

1

Avoid prolonged, excessive or repeated skin contact with used oil.

2

Apply a barrier cream to the skin before handling used oil.

3

Note the following removing oil from the skin: a Wash your hands thoroughly with soap and water. b Using a nail brush will help. c Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel or paraffin for washing.

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B2

MAINTENANCE

B2

SERVICE SCHEDULES

! WARNING Maintenance work must competent personnel.

only

be

by

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.

fluids

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.

done

A-3-1-1

! CAUTION Only use lubricants and hydraulic recommended by JCB Attachments.

Any defects found during the regular routine maintenance checks must be rectified before the equipment is used.

Daily

Monthly

Clean

Check (Breaker disconnected)

1

1

Torque tightness of all fasteners.

2

The hexagon bush in the nose casting for wear or damage.

3

The cutting steel shanks for excessive wear.

The breaker, its steels and its hoses.

Check (Breaker disconnected) 2

All hydraulic connections.

3

For damage to the breaker, its steels and its hoses.

Lubricate 1

Vibro-damped handle types only. Spray the trigger and all contacting parts with suitable lubricant.

Every 600 Operating Hours or Yearly (which ever occurs first.)

1

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Overhaul the breaker.

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B3

MAINTENANCE

B3

BREAKER DISMANTLING - HM 22, 25, 29

A

S R O 1

Using a press, remove roll pins Q from the nose.This releases latch R, latch plunger S and the plunger spring.

4

Prepare for oil spillage and remove the two upper barrel fixing capscrews. Remove the barrel A.

D

2

Unless 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’.

5

C

Push the piston C and piston feeder D out of the barrel. Remove 3 ‘O’ rings from the barrel.

A

F

B 3

Before commencing dismantling, clean externally. Remove the hoses. Remove the two lower barrel fixing capscrews. Separate the barrel A from the nose B.

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6

E

Unscrew and remove check valve E ensuring that the breaker is positioned as shown above so as to avoid losing the check valve ball F.

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B4

MAINTENANCE

B4

BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)

N

7

Remove the seals from the lower section of the barrel casting. A slide hammer will be necessary to remove the seal housing.

J

10 Remove screws (4 off each cover) from covers N (2 off), this will expose the handle mechanism.

Z

H G 8

Z

Remove the housing cap G and the spool H from the head J.

11 Unscrew the handle pivot pin Z nearest the trigger pin. Withdraw handles assemblies from the handles control bracket.

J L K 9

M

G

Remove the plug K, seal washer L, spring and trigger spool M from the head J. Examine seals on the head J and housing cap G.

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12 Remove vibration dampening springs.

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B5

MAINTENANCE

B5

BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)

P

T P

13 Remove the cover screw T to expose the charging screw.

16 Remove the four top cover retaining screws P and remove the cover.

Note: There are two long and two shorter retaining screws

U Y

T

W

14 Loosen the charging screw U slowly approximately 3 or 4 turns, listening for all the gas to escape. Refit the cover screw T.

17 Remove the trigger pin W and the ‘O’ ring seal Y from the head.

X

V

15 When you are sure that all the gas in the accumulator has been evacuated, remove the safety screw V from the head.

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18 Remove the diaphragm X from the head.

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B6

MAINTENANCE

B6

BREAKER INSPECTION - HM 22, 25, 29

D

1

C

A

Examine the piston C, piston feeder D and barrel A for signs of damage. Small scratches can be carefully removed with fine emery cloth.

4

Examine the seals for signs of wear. Pay particular attention to their lips. Obtain new seals if necessary or if the piston is changed.

J D C

A H G

2

Deep 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.

5

Examine the housing cap G and spool H for signs of damage. Obtain new components if necessary.

J F

M

L K

3

Examine the check valve ball F and ball seats for signs of damage or excessive wear. Obtain new components if necessary.

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6

Examine the plug K, seal washer L, spring and trigger spool M for signs of damage or wear.

Obtain new components if necessary.

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B7

MAINTENANCE

B7

BREAKER INSPECTION - HM 22, 25, 29 (cont’d)

nn

jj

S

ii

ff aa

R Q 7

Examine the roll pins Q, latch R, latch plunger S and plunger spring for signs of damage or wear.

Obtain new components if necessary.

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

X

cc

aa

8

Should 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.

11 Examine the diaphragm X for signs of damage.

Pay particular attention for signs of cracking around the diaphragm insert. Replace as necessary.

Note: A hydraulic press will be required to remove to remove the steel tool bush nn. See item 10.

ee

aa

9

Grip the spring ring aa with a suitable pair of pincers ee and remove. The sliding bush and other components can now be removed from the nose (see item 10).

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B8

MAINTENANCE

B8

BREAKER ASSEMBLY - HM 22, 25, 29

! CAUTION

O

Before commencing assembly, all components must be scrupulously cleaned.

A-3-1-4

V Note: During assembly, apply Multi Gasket Loctite 518 (JCB Part No. 4102/1212) to all joint faces. Use new seals and ‘O’ rings throughout.

3

Fit the trigger pin O into the handle bracket. Fit the handle bracket to the head. Treat the threads of the safety screw V with Loctite 270 and fit to the head.

4

Fit the handle assembly springs. Coat the contacting surface of the handle furthest from the trigger pin (see item 5) and fit to the handle bracket.

5

The illustration above shows the trigger handle after coating with a suitable lubricant before fitting.

X

Y

1

Place diaphragm X into the head, ensuring that the diaphragm insert is uppermost (as shown above). Fit new ‘O’ ring seal Y.

J M

L

K 2

Fit the trigger spool M, spring, seal washer L and plug K into the head J. Fit seal on head unit J.

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MAINTENANCE

B9

BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)

Z A ss tt

Z 6

zz

Treat the thread of the pivot pin Z with Loctite 270 and fit the pin where indicated.

9

Assemble the seals into the lower section of the barrel casting A. Ensure seal ss has the open face uppermost,seal zz is fitted in the same direction.

E

E

7

Check that all parts of the trigger and other parts in contact are well coated with lubricant. (see item 5)

F

10 Treat the threads E of the check valve with Loctite 542. Ensure that the ball F is clean and undamaged. Obtain a new seal. Assemble the check valve.

A J

H G 8

Fit the housing spool H and the housing seal G into the head J. Fit a new ‘O’ ring to the housing seal G.

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F

E

11 Fit the check valve into the barrel A. Always ensure that ball F has been fitted.

Issue 1

B10

MAINTENANCE

B10

BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)

A

N B 12 Bolt the barrel A to 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

15 Replace covers N (2 off).

A C

D

13 Fit 3 new seals into barrel A. Insert the piston C and piston feeder D into the barrel A.

A

B 14 Fasten the barrel A/nose B assembly onto the head assembly using the capscrews and a Gedore torque wrench (part no. 7200-01). See Torque Figures on Page A2.

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B11

MAINTENANCE

B11

CHARGING THE ACCUMULATOR - HM 22, 25, 29

CHARGING PROCEDURE

! 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.

1

Remove the slotted cover screw 1 from the breaker.

2

Using a 4 mm. Allen key 2, slowly loosen the charging screw approximately 3 turns. Do not remove the screw.

This procedure must not be carried out with the breaker (or pick) connected to a source of hydraulic supply.

3

Fit the 3/8 in. Dowty washer 5 to the charging adaptor 3 and screw into the breaker. Do not overtighten, hand tight is adequate.

4

Ensure that the nitrogen bottle outlet pressure is at zero and then connect the charging hose 4 to the charging adaptor 3.

5

Gradually increase the nitrogen bottle outlet pressure until the required level is reached (see Specification section).

6

Push in knob 6 on the charging adaptor 3 to engage the charging screw and tighten. Do not overtighten.

Charging adaptor (JCB part no. 929/05800) together with 3/8 in. BSP Dowty washer.

7

Connecting hose Suitable hose of minimum operating pressure 207 bar (3000 lbf/in2), together with female coupling (JCB part no.929/06303).

Shut the regulator valve on the nitrogen bottle and using the venting screw 7, release the trapped gas in the hose.

8

Disconnect the charging hose 4 and unscrew the charging adaptor 3 from the body of the breaker.

9

Finally, tighten the charging screw using a 4mm. Allen key 2 and refit the cover screw 1 after applying Loctite 270 to the threads.

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

d

CHARGING PRESSURE The charging pressure should not exceed 50 bar (800 lbf/in2). Refer to Specification section for specific accumulator pressures.

4 5 6

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3 7

1

X3

2

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B12

MAINTENANCE

B12

OPERATOR FAULT FINDING *The remedy in certain cases should be carried out by your JCB dealer Symptom

Possible Fault

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 trigger spool.

*The trigger spool should move approx.

5mm (0.2in.). Check lever mechanism.

Main spool jammed or damaged.

*Remove and check.

Clean all associated parts.

Striker piston seized.

*Remove and check for 'pick-up' on piston feeder or barrel. Replace any damaged parts.

Insufficient available pressure.

*Check Main Relief Valve 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 (Normally associated with violent shaking of hoses).

*Re-charge the accumulator

Hexagon bush in nose casting loose.

Apply JCB Retainer( High Strength ) and press back.

Insufficient flow.

*Check that the flow rate is between 18 - 22 l/min. (3.96 - 4.84 gal/min.).

Breaker lacks breaking power.

Breaker runs slow

Remedy

Note: For HM29 (30 litre.) flow rate 28 - 32l/min (6.16 - 7.04 gal/min).

Breaker runs hot.

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).

Inadequate cooling of hydraulic oil.

Check oil supply has adequate cooling.

Temperature should not exceed 80C (176F).

Specifications

Model

Length

Weight

929/92400 760 mm

25 kg

929/92500 720 mm

22 kg

929/92600 680 mm

22 kg

929/92700 730 mm 929/92900 730 mm

Steel Size mm (in) 32 x 160 (11/4 x 61/4) 22 x 82.5 (7/8 x 31/4)

Noise Level

Vibration

EHTMA Category Flow Rate

Pressure Range

Min. Relief Valve Settings

Acc. Gas Pressure

109 Lwa

4.0 m/s 2

C

18-22 L/Min 90-110 bar

110 bar

43 bar

106 Lwa

3.4 m/s 2

C

18-22 L/Min 69-86 bar

76 bar

38 bar

106 Lwa

3.4 m/s 2

C

18-22 L/Min 69-86 bar

76 bar

38 bar

29 kg

25 x 108 (1 x 41/4) 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

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

Noise Level Standard: Noise Level EC Directive 84/537/EEC (Lwa) Vibration Standard: Vibration Weighted RMS Acceleration ISO 8662 Part 5 (m/s2)

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B13

MAINTENANCE

B13

BREAKER HM26 (NON EU)

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B14

MAINTENANCE

B14

BREAKER HM26 (NON EU)

HM26 (NON EU) - Servicing It should be noted that, when servicing this breaker (shown on page B12), detail for the handle only reference should be made to Section C - Standard handle breakers(from 9803/1250 Issue 1).

The remainder of the breaker , head, barrel and nose sections, are covered in Section B - respective sections.

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B15

MAINTENANCE

B15

BREAKER - HM22, 25, 29

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Issue 1

C

C

MAINTENANCE CONTENTS

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Breaker dismantling - Standard and Vibro-damped

C1

Breaker inspection - Standard and Vibro-damped

C5

Breaker assembly - Standard and Vibro-damped

C7

Breaker dismantling - ‘D’ and ‘T’ picks

C8

Breaker inspection - ‘D’ and ‘T’ picks

C14

Breaker - ‘D’ and ‘T’ picks

C16

Charging the accumulator Equipment required Charging pressure Charging procedure

C19

Fault Finding

C20

Issue 1

C1

C1

MAINTENANCE BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED ! WARNING

! WARNING

Accumulator The breaker incorporates a pressure accumulator.

This accumulator is pressurised even when there is no hydraulic pressure to the breaker. Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death. This procedure must be carried out by a qualified person.

The breaker must be disconnected from its source of hydraulic power before any maintenance is carried out.

Note: Unless otherwise indicated, the following instructions apply to both the standard handle and vibro-handle type breakers.

1

Before commencing dismantling, thoroughly clean all external parts.

2

Remove the hoses. Remove the two lower barrel fixing capscrews. Separate the barrel A from the nose B.

3

The lower portion of the piston C and the seal housing and seal will be exposed.

4

Prepare for oil spillage and then remove the two upper barrel fixing capscrews. remove the barrel A.

5

Push the piston C and piston feeder D out of the barrel.

9803/1250

Issue 1

C2

MAINTENANCE

C2

BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

6

Unscrew and remove check valve E ensuring that the breaker is positioned as shown above so as to avoid losing the check valve ball F.

7

Remove the seals from the lower section of the barrel casting. A slide hammer will be necessary to remove the seal housing.

8

Remove the housing cap G and the spool H from the head J.

9

Remove the plug K, seal washer L, spring and trigger spool M from the head.

10 For standard handle breakers only, Using a press, remove roll pins N from the top cover and remove the trigger. Withdraw the trigger pin O.

9803/1250

11 For standard handle breakers only, remove the capscrew from inside each handle and remove the handles from the top cover.

Issue 1

C3

MAINTENANCE

C3

BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

12 For vibro-damped handle breakers only, remove the four top cover retaining screws P and remove the cover.

13 For vibro-damped handle breakers only, unscrew the handle pivot pin Z nearest the trigger pin. Withdraw the handle assembly from the control handles bracket.

14 For vibro-damped handle breakers only, withdraw the remaining handle assembly complete with handle pivot. Remove the springs.

15 For vibro-damped handle breakers only, using a press, remove roll pins Q from the nose. This releases latch R, latch plunger S and the plunger spring.

! WARNING Accumulator The breaker incorporates a pressure accumulator.

This accumulator is pressurised even when there is no hydraulic pressure to the breaker. Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death. Gas pressure must be released before carrying out further dismantling.

Note: Once gas has been released, a special charging tool (part no. 929/05800) is required to re-charge the accumulator. Re-charging the accumulator must only be undertaken by a suitably qualified person.

16 Remove the cover screw T to expose the charging screw.

9803/1250

Issue 1

C4

MAINTENANCE

C4

BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

17 Loosen the charging screw U slowly approximately 3 or 4 turns, listening for all the gas to escape. Refit the cover screw T.

18 For standard handle breakers only, when you are sure that all the gas in the accumulator has been evacuated, remove the safety screw V from the head.

19 For standard handle breakers only, remove the four capscrews and remove the cover from the head.

20 For vibro-damped handle breakers only,when you are sure that all the gas in the accumulator has been evacuated, remove the safety screw V from the head.

21 For vibro-damped handle breakers only, withdraw the trigger pin O. Remove the four capscrews and remove the handle bracket from the head.

22 Remove the diaphragm X and ‘O’ ring seal Y from the head.

9803/1250

Issue 1

C5

MAINTENANCE

C5

BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED

1

Examine the piston C, piston feeder D and barrel A for signs of damage. Small scratches can be carefully removed with fine emery cloth. Deep grooves or signs of pick-up (especially on the lower sealing portion of the piston) will require the replacement of the component.

2

Examine the check valve ball F and ball seats for signs of damage or excessive wear. Obtain new components if necessary.

3

Examine the seals for signs of wear. Pay particular attention to their lips. Obtain new seals if necessary.

4

Examine the housing cap G and spool H for signs of damage. Obtain new components if necessary.

5

For standard handle breakers only, examine the rubber bushes inside the handles for signs of damage. Fit new bushes if necessary. These bushes are a press fit inside the handles and can be removed by slitting their cores from the inside and driving out.

6

Examine the plug K, seal washer L, spring and trigger spool M for signs of damage or wear.

Obtain new components if necessary.

9803/1250

Issue 1

C6

MAINTENANCE

C6

BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED (cont’d)

7

Examine the roll pins Q, latch R, latch plunger S and plunger spring for signs of damage or wear.

Obtain new components if necessary.

9

Examine the bush inside the nose for signs of damage or wear. If it is necessary to remove the bush it can be pressed out from the top of the housing using a suitable hydraulic press of approximately 20 tonnes.

9803/1250

8

Examine the diaphragm X for signs of damage.

Pay particular attention for signs of cracking around the diaphragm insert. Obtain a new diaphragm if necessary.

Issue 1

C7

MAINTENANCE

C7

BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED ! CAUTION Before commencing assembly, all components must be scrupulously cleaned.

A-3-1-4

Note: During assembly, apply Multi Gasket Loctite 574 (JCB Part No. 4102/1201) to all joint faces.

1

Place diaphragm X into the head, ensuring that the diaphragm insert is uppermost (as shown above). Fit new ‘O’ ring seal Y.

2

Fit the trigger spool M, spring, seal washer L and plug K into the head.

3

For standard handle breakers only, insert the trigger pin O. Assemble the trigger onto the top cover and fit roll pins N using a press.

4

For standard handle breakers only, assemble the top cover onto the head and fit the four capscrews. Torque tighten the capscrews progressively (see Introduction section), ensuring theat the trigger pin remains free to move.

5

For vibro-damper handle breakers only, fit the trigger pin O. Assemble the handle bracket onto the head and fit the four capscrews. Torque tighten the capscrews progressively (see Introduction section), ensuring that the trigger pin remains free to move.

9803/1250

Issue 1

C8

MAINTENANCE

C8

BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)

6

Treat thread of safety screw V with Loctite 242 and fit the safety screw into the head.

7

For vibro-damped handle breakers only, fit the handle assembly springs. Fit the handle assembly furthest from the trigger pin complete with pivot pin into the handle bracket (see Step 14 of Dismantling).

8

For vibro-damped handle breakers only, fit the remaining handle assembly. Treat the thread of pivot pin Z with Loctite 242 and fit the pin. Spray the handles, trigger and all contacting parts with a suitable lubricant.

9

For vibro-damped handle breakers only, assemble the top cover onto the handle bracket.

Treat the threads of the top cover capscrews with Loctite 242 and torque tighten (see Introduction section).

10 For standard handle breaker only, fit the handles to the top cover with capscrews. Torque tighten the capscrews (see Introduction section).

9803/1250

11 Fit the housing spool H and housing seal G into the head. Fit a new ‘O’ ring to the housing seal.

Issue 1

C9

MAINTENANCE

C9

BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)

12 Assemble the seals into the lower section of the barrel casting. Ensure that the open faces of the seals are fitted as shown on inset.

13 Treat the thread of check valve E with Loctite 542.

Fit the check valve and its ball F into the barrel by offering the check valve to the barrel from underneath to avoid losing the ball.

14 Bolt the barrel to the nose with capscrews. Torque tighten the capscrews progressively (see Introduction section) using a Gedore narrow head torque wrench (part no. 7200-01). Do not use a standard torque wrench fitted with a universal joint as this distorts the torque setting.

15 Insert the piston C and piston feeder D into the barrel.

16 Assemble the head assembly onto the barrel/nose assembly and fit the capscrews. Torque tighten the capscrews progressively (see Introduction section) using a Gedore narrow head torque wrench (part no. 7200-01- see Step 14 above). Fit the hoses, ensuring that the hose with the female coupling is fitted to the top port of the head assembly.

17 Assemble the plunger spring, plunger S, and latch R into position in the nose. Using a press, insert roll pins Q to secure the mechanism.

9803/1250

Issue 1

C10

C10

MAINTENANCE BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS ! WARNING

! WARNING

Accumulator The breaker incorporates a pressure accumulator.

This accumulator is pressurised even when there is no hydraulic pressure to the breaker. Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death. This procedure must be carried out by a qualified person.

The pick must be disconnected from its source of hydraulic power and the oil drainer before any maintenance is carried out.

! WARNING Under no circumstances should an attempt be made to remove the handle when the pick is connected to a source of hydraulic power.

! CAUTION Before commencing assembly, all components must be scrupulously cleaned.

A-3-1-4

Note: Unless otherwise indicated, the following instructions apply to both the ‘D’ type and ‘T’ type breakers.

1

Disconnect hoses and collect any residual oil into a suitable container.

2

Cut the cable tie securing the hose gaiter 1 and remove the gaiter. Remove the hoses 2 from the adaptors 3. Remove the adaptors and seals 4 from the accumulator assembly.

3

Remove the four capscrews 5 together with washers 6 and remove the handle assembly.

4

If necessary, drift out the pivot pin 7 and remove the trigger 8 from the handle.

5

Remove the push pin 9 (‘D’ Type only). Remove the spring 10, trigger pin 11 and ‘O’ ring 12 from the accumulator assembly. Discard the ‘O’ ring.

9803/1250

Issue 1

C11

MAINTENANCE

C11

BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)

6

‘D’ Type only. Remove the retainer 13 with the bump stop 14. Remove and discard ‘O’ ring 15.

‘T’ Type only. Remove nose latch 16 with the shim assembly 17. Remove and discard ‘O’ ring 15.

7

‘T’ Type only. If necessary, remove roll pins 18 and 19 suing a press. Remove the latch 20, plunger 21 and spring 22.

8

Remove the accumulator/barrel/nose assembly from the upper end of the nose casting 23.

9

Apply light pressure to the top of slide rail 24 to compress spring 25 then swing the bottom of the slide rail clear of bump stop 26. Remove the slide rail and the spring. Repeat for the other side.

10 Remove slide bearing 27 and bump stop 26 from both sides then remove capscrews 28 to separate the accumulator assembly from the barrel/nose assembly.

9803/1250

11 Turn the accumulator assembly over. Withdraw housing cap 29 then remove and discard ‘O’ ring 30. Remove ‘O’ ring 31 from the recess in the accumulator assembly and discard the ‘O’ ring.

Withdraw spool 32 from the spool housing.

Issue 1

C12

MAINTENANCE

C12

BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d) ! WARNING Accumulator The breaker incorporates a pressure accumulator.

This accumulator is pressurised even when there is no hydraulic pressure to the breaker. Attempting to dismantle the accumulator without first releasing the pressure can cause injury or death. Gas pressure must be released before carrying out further dismantling.

Note: Once gas has been released, a special charging tool (part no. 929/05800) is required to re-charge the accumulator. Re-charging the accumulator must only be undertaken by a suitable qualified person.

12 Remove plug 33, seal 34, spring 35 and trigger spool 36.

13 Releasing Gas Pressure from the accumulator.

Remove the cover screw 37 to gain access to the charging screw 38. Insert a 4 mm allen key and slowly loosen the charging screw approximately 3 or 4 turns listening for all the gas to escape.

Tighten the charging screw approximately 3 or 4 turns. Refit the cover screw.

14 Dismantling the Accumulator Assembly (see WARNING). Remove the four capscrews 39 and separate the accumulator top 40 from the accumulator head 41. Remove the diaphragm 42 from the head.

15 Hold the barrel/nose assembly above the workbench with the check valve housing pointing downwards. Remove the check valve 43 with the check valve ball 44.

16 Using a suitable drift, push out the piston 45 and piston feeder 46 from the barrel 49. Separate the piston from the feeder. Remove and discard ‘O’ ring 47.

9803/1250

Issue 1

C13

MAINTENANCE

C13

BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)

17 Remove the two grub screws 48 from the lower end of the barrel 49 (one each side).

18 Clamp the barrel/nose assembly in a vice and unscrew the now 50 from the barrel 49, using a ‘C’ spanner.

19 Remove seal 51 and seal housing 52 from the lower end of the barrel 49. Using a slide hammer, remove seal 53 from seal housing 52. Discard the seals.

9803/1250

Issue 1

C14

MAINTENANCE

C14

BREAKER INSPECTION - ‘D’ and ‘T’ PICKS

1

‘T’ Type only. Examine the roll pins 18 and 19, latch 20, plunger 21 and plunger spring 22 for signs of damage or wear. Obtain new components if necessary.

2

Examine the housing cap 29 and spool 32 for signs of damage. Obtain new components if necessary.

3

Examine the plug 33, seal 34 and trigger spool 36 for signs of damage or wear. Obtain new ocmponents if necessary.

4

Examine the diaphragm 42 for signs of damage.

Pay particular attention for signs of cracking around the diaphragm insert. Obtain a new diaphragm if necessary.

5

Examine the check valve ball 44 and ball seat in check valve 43 for signs of damage or excessive wear. Obtain new components if necessary.

6

Examine the piston 45, piston feeder 46 and barrel 49. Small scratches can be carefully removed with fine emery cloth. Deep grooves or signs of pick-up (especially on the lower sealing portion of the piston) will require the replacement of the component.

9803/1250

Issue 1

C15

MAINTENANCE

C15

BREAKER INSPECTION - ‘D’ and ‘T’ PICKS (cont’d)

7

Examine slide rails 24 and springs 25 for signs of excessive wear, damage or deformation. Replace if necessary.

9803/1250

8

Examine slide bearings 26 and bump stops 27 for signs of damage or excessive wear. Replace if necessary.

Issue 1

C16

MAINTENANCE

C16

BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS ! CAUTION Before commencing assembly, all components must be scrupulously cleaned.

A-3-1-4

Note: Unless otherwise indicated, the following instructions apply to both the ‘D’ type and ‘T’ type breakers.

Note: During assembly, apply Multi Gasket Loctite 574 (JCB Part No. 4102/1201) to all joint faces. Lightly lubricate all hydraulic components with hydraulic fluid prior to assembly.

1

Insert new seal 51 into the lower end of barrel 49.

Assemble new seal 53 to seal carrier 52 and insert into barrel 49. Ensure the seals are fitted as shown.

2

Clamp the barrel 49 in a vice. Apply Loctite 242 to nose 50 and screw into the barrel using a ‘C’ spanner.

3

Apply Loctite 242 to grub screws 48 and fit into the lower end of barrel 49 (one each side).

4

Insert piston 45 into the upper end of barrel 49. Fit new ‘O’ ring 47 to piston feeder 46 and slide the piston feeder into the piston.

5

Treat the thread of check valve 43 with Loctite 542. Hold the barrel/nose assembly above the workbench with the check valve housing pointing downwards and fit the check valve with the check valve ball 44.

9803/1250

Issue 1

C17

MAINTENANCE

C17

BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)

6

Fit the diaphragm 42 into the accumulator head 41, ensuring the diaphragm insert is uppermost.

Assembly the accumulator top 40 onto the head and fit the four capscrews 39. Torque tighten the capscrews to 80 Nm (8.1 kgf m, 59 lft ft).

7

Turn the accumulator assembly over. Insert trigger spool 36 into accumulator assembly. Fit spring 35, seal 34 and plug 33.

8

Slide spool 32 into spool housing. Fit new ‘O’ ring 30 to housing cap 29 and insert into accumulator assembly, followed by new ‘O’ ring 31.

9

Assemble the accumulator assembly onto the barrel/nose assembly and fit the capscrews 28.

Torque tighten the capscrews to 135 Nm (14 kgf m, 100 lbf ft). Fit bump stops 26 to the heads of the capscrews and assemble slide bearings 27 (both sides). Charge the accumulator, refer to page C19.

10 Fit spring 25 and slide rail 24 as shown. Apply light pressure to the top of the slide rail to compress the spring then swing the bottom of the slide rail over the bump stop 26. Repeat for the other side.

9803/1250

11 Fit the accumulator/barrel/nose assembly into the upper end of the casting 23.

Issue 1

C18

MAINTENANCE

C18

BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)

12 ‘T’ Type only. If dismantled, fit the spring 22, plunger 21 and latch 20 into the nose latch. Using a press, insert roll pins 18 and 19 to secure the mechanism.

13 Fit new ‘O’ ring seal 15 onto the nose 52, taking care not to damage it on the exposed thread. ‘T’ type only. Fit the shim assembly 17 and the nose latch 16. ‘D’ Type only. Fit the bump stop 14 and the retainer 13.

14 Lubricate a new ‘O’ ring 12 and feed it into the hole in the top of the accumulator assembly; once inside, the ‘O’ ring will expand to fill the groove. Fit the trigger pin 11 and spring 10. ‘D’ type only. Fit push pin 9.

15 If dismantled, fit trigger 8 to the handle and drive in pivot pin 7 to secure.

16 Assemble the handle assembly onto the outer casing and fit washers 6 and capscrews 5. Note that two of the capscrews are longer than the others.

17 Assemble seals 4 and adaptors 3 to the accumulator assembly. Fit hoses 2, ensuring that the hose with the female coupling is fitted to the top port of the accumulator head. Fit the hose gaiter 1 and secure with a cable tie.

Issue 1

C19

MAINTENANCE

C19

CHARGING THE ACCUMULATOR ! WARNING

CHARGING PROCEDURE

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.

Note: For ‘D’ and ‘T’ picks, access must first be gained to the accumulator assembly by carrying out Steps 1 to 8 (excluding step 7) of Breaker Dismantling.

1

Remove the slotted cover screw 1 from the breaker.

This procedure must not be carried out with the breaker (or pick) connected to a source of hydraulic supply.

2

Using a 4 mm Allen key 2, slowly loosen the charging screw approximately 3 turns. Do not remove the screw.

3

Fit the 3/8 in. Dowty washer to the charging adaptor C and screw into the breaker. Do not overtighten, hand tight is adequate.

4

Ensure that the nitrogen bottle outlet pressure is at zero and then connect the charging hose D to the charging adaptor C.

5

Gradually increase the nitrogen bottle outlet pressure until the required level is reached (see Specification section).

During charging, the breaker must be securely mounted in the upright position. This prevents the breaker falling over whilst charging, thereby preventing uncontrolled escape of gas.

EQUIPMENT REQUIRED a

Nitrogen bottle Minimum residual pressure 70 bar (100 lbf/in2).

b

Regulator (with contents and outlet gauge) Outlet pressure would be controllable up to 55 bar (800 lbf/in2)

6

Push in knob 6 on the charging adaptor C to engage the charging screw and tighten. Do not overtighten.

c

Charging adaptor (JCB part No. 929/05800) together with 3/8 in. BSP Dowty washer.

7

d

Connecting hose Suitable hose of minimum operating pressure 207 bar (3000 lbf/in2), together with female coupling (JCB part No. 929/06303)

Shut the regulator valve on the nitrogen bottle and using the venting screw 7A, release the trapped gas in the hose.

8

Disconnect the charging hose D and unscrew the charging adaptor C from the body of the breaker.

9

Finally, tighten the charging screw using a 4 mm Allen key 2 and refit the cover screw 1 after applying Loctite 242 to the threads.

CHARGING PRESSURE The charging pressure should not exceed 50 bar (725 lbf/in2). Refer to Specification section for specific accumulator pressures.

9803/1250

Note: For ‘D’ and ‘T’ picks, refit the accumulator assembly by carrying out Steps 11 to 17 of Breaker Assembly. Seals need not be replaced providing they are serviceable.

Issue 1

C20

C20

MAINTENANCE FAULT FINDING

*The remedy in certain 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 trigger spool.

*The trigger spool should move approx. 5 mm (0.2 in). Check lever mechanism.

Main spool jammed or damaged.

*Remove and check.

Clean all associated parts.

Striker piston seized.

*Remove and check for ‘pick-up’ on piston feeder or barrel.

Replace any damaged parts.

Insufficient available pressure.

*Check Main Relief Valve - for settings refer to Specification section.

Low accumulator gas pressure (Normally associated with violent shaking of hoses).

*Re-charge the accumulator as detailed in this section.

Hexagon bush in nose casting loose.

Apply JCB Retainer ( High Strength ) and press back.

Insufficient flow.

*Check the flow rate - for settings refer to Specification section.

Cold oil

Warm up the oil supply. Optimum temperature 20 - 70ºC (68 - 158 ºF).

High return line back pressure.

*Check return line back-pressure.

Pressure should not exceed 12 bar (174 lbf/in2).

Incorrect oil.

Use only JCB Special Hydraulic Oil (part no. 4002/0224).

Inadequate cooling of hydraulic oil.

Check oil supply has adequate cooling. Temperature should not exceed 80 ºC (176 ºF).

Breaker lacks breaking power.

Breaker runs slow.

Breaker runs hot.

9803/1250

Issue 1

D

D

SPECIFICATION CONTENTS

JCB hydraulic breakers Standard Breakers Vibro-damped breakers ‘D’ and ‘T’ breakers Noise and vibration data

9803/1250

D1 D1/D2 D2 D3

Issue 1

D1

D1

SPECIFICATION JCB HYDRAULIC BREAKERS

STANDARD BREAKERS Breaker weight Model Nos. 929/05400 & 05600 Model Nos. 929/07200 & 08200

20 kg 26 kg

44 lb 57 lb

Breaker length Model Nos. 929/05400 & 05600 Model Nos. 929/07200 & 08200

910 mm 1050 mm

36 in.

41 in.

Accumulator gas pressure (Nitrogen) Model Nos. 929/05400 & 05600 Model Nos. 929/07200 & 08200

38 bar 50 bar

551 lb/in2 725 lb/in2

Hydraulic supply flow rate Model Nos. 929/05400, 05600 Model No. 929/07200 Model No. 929/08200

18 - 22 l/min 18 - 22 l/min 28 - 32 l/min

3.96 - 4.84 gal/min 3.96 - 4.84 gal/min 6.20 - 7.00 gal/min

Hydraulic supply pressure range Model Nos. 929/05400 & 05600 Model Nos. 929/07200 & 08200

69 - 86 bar 90 - 110 bar

1000 - 1247 lb/in2 1300 - 1600 lb/in2

Hydraulic supply relief valve setting Model Nos. 929/05400 & 05600 Model Nos. 929/07200 & 08200 All models

76 bar min 1100 lb/in2 min 138 bar max.

2000 lb/in2 max.

Hydraulic return line pressure

12 bar max.

174 lb/in2 max.

Breaker blow frequency

1500 blows/min

-

Breaker shank size Model No. 929/05400 Model No. 929/05600 Model No. 929/07200 & 08200

22 mm 25 mm 32 mm

7/8 in.

1 in.

1 1/4 in.

Hydraulic supply oil type

JCB Special Hydraulic Oil (part no. 4002/0224)

EHTMA Category

‘C’ or ‘D’

VIBRO-DAMPED BREAKERS Breaker weight Model Nos. 929/05300 & 05500 Model Nos. 929/07400 & 08300

22 kg 28 kg

44 lb 62 lb

Breaker length Model Nos. 929/05300 & 05500 Model Nos. 929/07400 & 08300

930 mm 1090 mm

36 in.

43 in.

Accumulator gas pressure (Nitrogen)

50 bar

725 lb/in2

Hydraulic supply flow rate Model Nos. 929/05300 & 05500 Model No. 929/07400 Model No. 929/08300

18 - 22 l/min 18 - 22 l/min 28 - 32 l/min

3.96 - 4.84 gal/min 3.96 - 4.84 gal/min 6.20 - 7.00 gal/min

9803/1250

Issue 1

D2

D2

SPECIFICATION JCB HYDRAULIC BREAKERS (cont’d)

VIBRO-DAMPED BREAKERS (cont’d) Hydraulic supply pressure range Model Nos. 929/05300 & 05500 Model Nos. 929/07400 & 08300

69 - 86 bar 90 - 110 bar

1000 - 1247 lb/in2 1300 - 1600 lb/in2

Hydraulic supply relief valve setting Model Nos. 929/05300 & 05500 Model Nos. 929/07400 & 08300 All models

76 bar min.

117 bar min.

138 bar max.

1100 lb/in2 1700 lb/in2 min.

2000 lb/in2 max.

Hydraulic return line pressure

12 bar max.

174 lb/in2 max.

Breaker blow frequency

1500 blows/min

-

Breaker shank size

32 mm

1.25 in.

Hydraulic supply oil type

JCB Special Hydraulic Oil (part no. 4002/0224)

EHTMA Category

‘C’ or ‘D’

‘D’ and ‘T’ BREAKERS Breaker weight (Dry with hoses) ‘D’ Handle ‘T’ Handle

12 kg 14 kg

26.4 lb 28.6 lb

Breaker length ‘D’ Handle ‘T’ Handle

645 mm TBA mm

25.4 in.

TBA in.

Accumulator gas pressure (Nitrogen)

33 bar

480 lb/in2

Hydraulic supply flow rate

15 - 20 litre/min

3.3 - 4.5 gal/min

Hydraulic supply pressure range

50 - 65 bar

725 - 945 lb/in2

Hydraulic supply relief valve setting

TBA bar min.

TBA bar max.

TBA lb/in2 min.

TBA lb/in2 max.

Hydraulic return line pressure

TBA bar max.

TBA lb/in2 max.

Breaker blow frequency

1500 blows/min

-

Breaker shank size

2.22 mm

0.875 in.

Hydraulic shank size

JCB Special Hydraulic Oil (part no. 4002/0224)

ETHMA Category

‘C’

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Issue 1

D3

D3

SPECIFICATION NOISE AND VIBRATION DATA

Model No.

Handle Type

Noise Level EC Directive 84/457/ EEC (LWA)

Vibration Weighted RMS Acceleration ISO 8662 Part 5 (m/s2)

929/05300

Vibro-Damped

111

5.5

929/05400

Standard

111

18.9

929/05500

Vibro-Damped

111

5.5

929/05600

Standard

111

18.9

929/07400

Vibro-Damped

107

5.4

929/07200

Standard

107

16.6

929/08300

Vibro-Damped

108

6.0

929/08200

Standard

108

17.1

929/12900

‘D’ Type

103

5.7

929/20400

‘T’ Type

103

5.7

9803/1250

Issue 1

E1

E1

CONTENTS HYDRAULIC POWER PACKS SAFETY FIRST - YOURS AND OTHER PEOPLE’S

9803/1250

Safety first - yours and other peoples

E2

Safety check list

E2

Lubricants - Health and Safety

E4

Identifying your machine

E5

Hydraulic Powerpacks

E6

Engine and electrical system

E7

Hydraulic circuits

E8

Issue 1

E2

E2

INTRODUCTION HYDRAULIC POWER PACKS SAFETY FIRST - YOURS AND OTHER PEOPLE’S

All hydraulic equipment can be hazardous. When a hydraulic powerpack is correctly operated and properly maintained, it is a safe machine to work with. But when correct operation and maintenance routines are not followed, the machine can be a danger to you (the operator) and others.

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

But safety is not just a matter of responding to the warnings.

All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

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

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. Do not assume anything.

Remember BE CAREFUL BE ALERT BE SAFE

SAFETY CHECK LIST GENERAL SAFETY ! WARNING

! WARNING

Handbook You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the instructions before operating the machine. If there is anything that you do not understand, ask your employer or JCB Dealer to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook readily available or if there is anything on the machine that you do not understand.

Clothing You can be injured if you do not wear correct clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: hard hat, safety shoes, safety glasses, a well fitting overall, ear protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

! WARNING

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

Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Renew unreadable and missing decals before operating the machine. Make sure replacement parts include warning decals where necessary.

OPERATING SAFETY

! WARNING

! WARNING Regulations Obey all laws, worksite and local regulations which affect you and your machine.

! WARNING

! WARNING

Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are complete before using the machine.

Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practicing them. Practice away from the worksite on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

! WARNING Hydraulic Tools Hydraulic tools can be dangerous. Observe all safety instructions relevant to the tool you will be operating. If in any doubt, consult you JCB Dealer.

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! WARNING Exhaust Gasses Breathing the machine exhaust gases can harm and possibly kill you. Do not operate in closed spaces without making sure there is good ventilation.

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E3

INTRODUCTION HYDRAULIC POWER PACKS SAFETY CHECK LIST (continued) ! WARNING

! WARNING

Communications Bad communications can cause accidents. Keep people around informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

Petrol Petrol is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

! WARNING

! WARNING

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in a closed area where there is flammable material, vapour or dust.

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

! WARNING Hot Surfaces Under normal working conditions the engine components, particularly the exhaust system, will get hot - DO NOT TOUCH. The hydraulic oil, pump, valve and tank can also reach temperatures high enough to burn - DO NOT TOUCH.

! WARNING Noise Excessive noise can be hazardous to your health. Always wear ear defenders when operating the machine.

MAINTENANCE SAFETY

! WARNING Fires Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioide, dry chemical or foam extinguishers. Contact your nearest Fire Department as quickly as possible. Firefighters should use self-contained breathing apparatus.

! WARNING Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers.

! WARNING Repairs Do not try to do repairs or any type of maintenance work which you do not fully understand, get the work done by a specialist engineer.

! WARNING Modifications Non-approved modifications can cause injury and damage.

Contract your JCB Dealer before modifying the machine.

! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

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INTRODUCTION

E4

HYDRAULIC POWER PACKS 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.

First Aid 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.

Handling Waste Disposal New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Used Oil Used oils contain harmful contaminants. Here are pre cautions to protect your health when handling used oil.

1

Avoid prolonged, excessive or repeated skin contact with used oil.

2

Apply a barrier cream to the skin before handling used oil.

3

Note the following removing oil from the skin: a

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.

Wash your hands thoroughly with soap and water.

b Using a nail brush will help. c

Use special hand cleansers to help clean dirty hands.

d Never use petrol, diesel fuel or paraffin for washing.

e Avoid skin contact with oil soaked clothing. f

Do not keep oily rags in pockets.

g Wash dirty clothing before reuse. h Throw away oil soaked shoes.

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E5

INTRODUCTION HYDRAULIC POWER PACKS IDENTIFYING YOUR MACHINE

Machine Serial Number

Engine Serial Number

Your machine is stamped with a serial number. The machine serial number can help you to find out what type of equipment you have. Your machine is stamped with both model and serial number and they can be found on top of the spacer plate X between the engine and hydraulic tank.

On Trojan III, Robin diesel engine models, the serial number can be found on pump mounting plate above the pump.

The engine will also have a serial number. Its position depends on which model you are operating. Consult your engine manufacturer’s handbook for details.

On all machines, the model number A is the first group of eight digits and the serial number B is the second group of seven digits.

X A B

C009340

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INTRODUCTION

E6

HYDRAULIC POWER PACKS

The range of hydraulic powerpacks are categorised by EHTMA as Category ‘C’ or ‘D’ hydraulic powerpacks and can be safely used with any hydraulic tool displaying the EHTMA ‘C’ or ‘D’ decals as shown below.

c

D

20LPM AT 138 BAR ETHMA CATEGORY

30LPM AT 138 BAR ETHMA CATEGORY

TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "C" POWERPACKS

TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "D" POWERPACKS

! WARNING You must understand and follow the instructions in this manual and any accompanying manuals. If you are unsure about anything ask your dealer or employer. Do not guess, or you or others could be killed or seriously injured.

General Description The JCB Hydraulic powerpacks have been specially developed to provide a lightweight source of portable hydraulic power for the JCB handheld hydraulic breakers and tools.

Despite their simple construction, the powerpacks incorporate many special features such as automatic, energy saving, engine speed control, a variable hydraulic flow and a unique hydraulic circuit design (patent applied for) which eliminates totally any possibility of pulsation damage to the oil cooler.

All the major components are enclosed in a fully welded tubular frame which also provides easy hand holds to maximise portability. A balanced lifting point is also provided.

This manual covers the JCB BEAVER III, Compact III, Trojan III, Duopower III and Micro Powerpacks. to operate the powerpack efficiently and safely you must know the powerpack and have the skill to use it. It is assumed that personnel carrying out maintenance have at least a sound knowledge of workshop practice, safety procedures and general techniques associated with the repair of hydraulic equipment.

Note: It is important to quote the serial number when making repairs or ordering parts.

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INTRODUCTION

E7

HYDRAULIC POWER PACKS ENGINE AND ELELCTRICAL SYSTEM Engine

Electrical System

The hydraulic powerpacks are fitted with different engines to give rated outputs as follows:

The electrical system is a 12V negative earth system. The machine is fitted with a single 12V battery.

Model

Type

Performance

Consult the Engine Manufacturer’s Handbook for details of the engine electrical circuits.

Beaver III

Honda GX240 Suzuki V270 Yanmar L70E Lombardi 15LD

8 HP (6 kW) 9 HP (6.7 kW) 7 HP (5.2 kW) 6.7 Hp (5 kW)

Compact III

Honda GX160

5.3 HP (4 kW)

Trojan III

Robin DY 35D Yanmar L100AE Honda GX340 Honda GX390

8 HP (6 kW) 10 HP (7.5 kW) 11 Hp (8.2 kW) 13 Hp (9.7 kW)

Micro

Honda GX160

5.3 Hp (4 kW)

Duopower III

Briggs and Stratton Vanguard

18 HP (13.4 kW)

The performance figures quoted are produces at a speed of 3600 rev/min (maximum permissible engine speed).

Engine speed is controlled automatically by a small hydraulic ram which is activated by the hydraulic circuit oil pressure.

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INTRODUCTION

E8

HYDRAULIC POWER PACKS HYDRAULIC CIRCUITS Description Bearer III and Compact III powerpacks are fitted with an hydraulic circuit capable of delivering 0 - 20 litres/min. Trojan III powerpacks are fitted with either a 0 - 20 litres/min or a 0 30 litres/min. hydraulic circuit depending on the model number. Duopower III powerpacks provide two independent variable flow outputs at 0 - 20 litres/min. which can be combined to give a single 0 - 40 litres/min. output. Full details are provided in Section D - Specification.

A brief description or each type of circuit is given below.

20 Litres/min Hydraulic Circuit The reservoir for the circuit is the hydraulic oil tank T, which contains a suction filter B, to prevent any dirt particles from being drawn into the pump D and return filter A to strain the returning oil. Hydraulic oil is drawn from the tank T, through the oil cooler C by the engine driven hydraulic pump D. The hydraulic circuit is self governing in that, although the pump output is directly proportional to the speed of the engine, the system pressure is related only to the power demanded to push the oil around the circuit and operate whatever tool is connected.

Oil from the hydraulic pump D is fed under pressure to a control valve which consists of two main parts: a

A relief valve E which controls the maximum working pressure of the system (see Operation Section).

b

An output control valve F which directs the flow of oil either to the tool or back to the hydraulic tank T.

30 Litres/min Hydraulic Circuit In these hydraulic circuits, extra components are fitted to prevent damage occurring to the hydraulic pump. An additional suction filter B is fitted to feed an anti-cavitation tee G. The anti-cavitation tee ensures that the negative pressure generated at the pump suction does not drop low enough for cavitation to occur.

As with the 20 litres/min powerpacks, the hydraulic circuit is also self-governing and the operation is similar.

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INTRODUCTION

E9

HYDRAULIC POWER PACKS HYDRAULIC CIRCUITS (continued) Description (continued) Duopower 40 Litres/min Hydraulic Circuit The reservoir for the circuit is the hydraulic oil tank T which contains suction filters B to prevent any dirt particles from being drawn into the pumps D, and return filter A to clean the returning oil.

Hydraulic oil is drawn from the tank T, through the oil cooler C by the engine driven pumps D. The 20 litres/min flow of hydraulic oil from each pump D is fed to control valves E and F. when the stop valve G is closed (lever to the left), each control valve will supply between 0 and 20 litres/min, the output control lever of each valve selecting the individual flows independant of each other.

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To provide 40 litres/min maximum from control valve E (upper valve on the power pack(, the stop valve G must be opened (lever to the right). Control valve F must be set to 20 litres/min using the output control lever and no connection should be made to the quick release couplings on this valve.

Oil from the front section of the pump D is fed via the open stop valve G, through the check valve H and combines with the flow from the rear pump into the directional flow valve E. The returning oil from each control valve is combined at the return manifold J, and then to the tank T via the return filter A.

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E10

OPERATION HYDRAULIC POWER PACKS CONTENTS

Introduction

E11

Before operating the machine

E11

Before starting the engine

E11

Honda GX160, GX240, GX340 and GX390 engines: Starting and stopping

E12

Suzuki V270 engines: Starting and stopping

E13

Yanmar L70E and L100E engines: Starting and stopping

E14

Lombardi 15LD315 engines: Starting and stopping

E15

Robin DY35D engine: Starting and stopping

E16

Briggs and Stratton Vanguard engine:

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Starting and stopping

E17

Operating in low temperatures

E18

Operating in high temperatures

E18

Hydraulic output control and feed and return connectors

E18

Connecting/disconnecting hoses

E19

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OPERATION

E11

HYDRAULIC POWER PACKS INTRODUCTION This chapter is arranged to guide you step-by-step through the task of learning how to operate the machine. Read it through from beginning to end. By the end of the chapter you should have a good understanding of the machine and how to operate it.

Pay particular attention to all safety messages. They are to warn you of possible danger. Do not just rear them; think about what they mean. Understand the dangers and how to avoid them. If there is anything you do not understand, ask you JCB Dealer. He will be pleased to advise you.

When you have learned where the controls are and what they do, practise using them. Practise using the machine is a safe place, clear of other people. Get to know the ‘feel’ of the machine and its controls.

Finally, do not rust the job of learning. Take you time and talk it safely.

Remember BE CAREFUL BE ALERT BE SAFE

Before Operating the Machine

Before Starting the Engine

The following checks should be made each time you return to the machine after leaving it for a period of time. All these checks concern the serviceability of the machine. Some concern your safety.

Note: If you will be operating the machine in either very cold or very hot conditions, refer to Operating in Low Temperatures or Operating in High Temperatures.

1

1

Position the Machine

Check for Cleanliness a a

Remove dirt and debris, especially from around the linkages, rams and hydraulic oil cooler.

2

b Clean all safety decals. Replace any that are mssing or cannot be read.

2

Complete a Pre-start Inspection a

b Ensure that all hydraulic couplings are fully serviceable. Refer to Hydraulic Couplings.

Inspect the machine and hoses generally for signs of damage and missing parts.

c b Check for fluid and fuel leakages beneath the machine.

Check for Security a

Check Hydraulic Oil Level a

3

Check the security of the hinged frame.

b Make sure the fuel filler cap is tightly closed.

4

If you have not already done so, complete a prestart inspection. Refer to Before Operating the Machine (opposite).

Check for Damage a

3

Ensure the machine is positioned safely.

Check the hydraulic oil level and add as necessary.

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Check Engine Oil Level a

4

Ensure that any hydraulic tools you are planning to use are compatible with the model of the machine you are using, see Specification.

Check the engine oil level and add oil as necessary.

Check Hydraulic Oil Level a

Ensure that you have adequate fuel for the job. Top up the fuel tank as necessary, taking care not to overfill. Never refuel with the engine running.

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OPERATION

E12

HYDRAULIC POWER PACKS HONDA GX160, GX240, GX340 AND GX390 ENGINES Starting 1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

On recoil start machines, turn the engine switch A to the ‘On’ position.

3

Turn on the fuel by setting the fuel On/Off control B to the ON position.

4

Move the choke control C to the CLOSE position.

If the engine is warm or the air temperature is high, the choke control should be set to the OPEN position.

5

Set the hydraulic output control (see page E18) to the OFF position.

6

Recoil Start Models Pull the starter grip E lightly until resistance is felt, then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

Electric Start Models Turn the keyswitch A to the ‘Start’ position and hold it there until the engine starts. Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again.

When the engine starts, allow the keyswitch A to return to the ‘Run’ position.

Note: The engines are fitted with an Oil Alert system which is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. The oil alert system will automatically shut down the engine before the oil in the crankcase can fall below a safe limit.

If the Oil Alert system has shut down the engine then the Oil Alert indicator will flash when you attempt to restart the engine.

7

As the engine warms up, gradually move the choke control C to the OPEN position.

8

Set the hydraulic output control (see page E18) to give the required hydraulic output.

Stopping 1

Turn the engine switch/keyswitch A to the ‘Off’ position.

2

Turn off the fuel by setting the fuel on/Off control B to the OFF position.

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OPERATION

E13

HYDRAULIC POWER PACKS SUZUIK V270 ENGINES Starting 1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

Turn on the fuel by setting the fuel On/Off control A to the ON position.

3

Move the choke control B to the left when the engine is cold.

If the engine is warm or the air temperature is high, leave the choke control in the right hand position.

4

Set the throttle control C to the FAST position.

5

Set the hydraulic output control (see page E18) to the OFF position.

6

Pull the starter grip lightly until resistance is felt, then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

7

As the engine warms up, gradually return the choke control B to the right.

8

Set the hydraulic output control (see page E18) to give the required hydraulic output.

Stopping 1

Set the throttle control C to the SLOW position.

2

Turn off the fuel by setting the fuel On/Off control A to the OFF position.

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OPERATION

E14

HYDRAULIC POWER PACKS YANMAR L70E AND L1003 ENGINES Starting 1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

Turn on the fuel by setting the fuel On/Off control A to the ON position.

3

Set the engine speed control B to the RUN/START position and tighten the knob to lock in this position.

4

Set the hydraulic output control (see page E18) to the OFF position.

5

Start the engine as follows: Recoil Start Models Use the starter grip D to turn the engine over until compression is reached, then push down the decompressor control C. Pull the starter grip D briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

Electric Start Models Insert the key E, turn to the ‘Start’ position and hold it there until the engine starts. Do not use the electric starter for more than 10 seconds at a time. If the engine fails to start , release the key and wait 15 seconds before operating the starter again.

When the engine starts, return the key to the ‘Run’ position. Do not remove the key.

6

After starting, allow the engine to idle for a few minutes then slacken the engine speed control B. Temperature

Idling Time

Below - 20 ºC - 20 ºC to - 10 ºC - 10 ºC to 5 ºC above 5 ºC

5 minutes 2 minutes 1 minute 20 seconds

In cold weather if your engine is hard to start, remove rubber plug E and add 2 c.c. of engine oil before starting.

7

Set the hydraulic output control (see page E18) to give the required hydraulic output.

Stopping 1

Move the speed control B to the STOP position.

2

If an electric start motor, turn the key F to the ‘Off’ position and remove from the switch.

3

Turn off the fuel by setting the fuel On/Off control A to the OFF position.

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OPERATION

E15

HYDRAULIC POWER PACKS LOMBARDINI 15LD315 ENGINE Starting 1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

Set the engine speed at 50% by slackening wingnut C and setting the throttle control A approximately midway between the MIN and MAX marks. Tighten the wingnut C.

3

Set the hydraulic output control (see page E18) to the OFF position.

4

Recoil Start Models Pull the starter grip D lightly until resistance is felt, then pull briskly. Do not allow the starter grip to snap back against the engine. return it gently to prevent damage.

Electric Start Models Insert the key in the control panel. When the key is turned to Position 1 the WARNING light will illuminate; turning the key to Position 2 will start the engine. Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again.

When the engine starts, release the key which will return to Position 1.

5

6

After starting, allow the engine to idle for a few minutes then slacken wingnut C. Temperature

Idling Time

Below - 20 ºC - 20 ºC to - 10 ºC - 10 ºC to 5 ºC above 5 ºC

5 minutes 2 minutes 1 minute 20 seconds

Set the hydraulic output controls (see page E18) to give the required hydraulic output.

Stopping 1

Set the stop lever B to the STOP position.

2

If an electric start model, turn the key to the OFF position and remove it from the control box.

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OPERATION

E16

HYDRAULIC POWER PACKS ROBIN DY 35D ENGINE Starting 1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

Turn the engine Start/Stop switch A to the START position.

3

Turn on the fuel by setting the fuel On/Off control B to the ON position.

4

Set the hydraulic output control (see page E18) to the OFF position.

5

Recoil Start Models Pull the starter grip C lightly until resistance is felt, then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

Electric Start Models Turn the starter key D to the START position and hold it there until the engine starts. Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again.

When the engine starts, release the key and allow to return to the RUN position.

6

Set the hydraulic output control (see page E18) to give the desired hydraulic output.

Stopping 1

Set the engine Start/Stop switch A to the STOP position.

2

If an electric start model, turn the key D to the STOP position and remove from the switch.

3

turn off the fuel by setting the fuel On/Off control B to the OFF position.

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OPERATION

E17

HYDRAULIC POWER PACKS BRIGGS & STRATTON VANGUARD ENGINE Starting

8

As the engine warms up, gradually return the choke control A to the RUN position.

9

Set the throttle control C to give the desired engine speed.

1

Complete the Before Operating the Machine and Before Starting the Engine procedures given on page E11.

2

Set the choke control A to the CHOKE position. If the engine is warm or the air temperature is high, the choke control should be set to the RUN position.

10 Set the hydraulic output control (see page E18) to give the required hydraulic output.

3

Turn on the fuel by setting the fuel shut-off control B to the ON (horizontal) position.

Stopping

4

Set the throttle control C to the SLOW position.

5

Set the hydraulic output control (see page E18) to the OFF position.

6

Set the rocker switch to the ON position.

7

Recoil Start Models

1

Set the rocker switch to the OFF position.

2

Turn off the fuel by setting the fuel shut-off control B to the OFF (vertical) position.

3

If an electric start model, turn the starter key to the OFF position and remove from the switch.

Pull the starter grip D lightly until resistance is felt, then pull briskly. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

Electric Start Models Insert the key in the keyswitch. Turn the key to the START position and hold it there until the engine starts.

Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again.

When the engine starts, release the key.

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OPERATION

E18

HYDRAULIC POWER PACKS OPERATING IN HIGH AND LOW TEMPERATURES Operating in Low Temperatures

Operating in High Temperatures

In low temperature situations, take the following precautions.

They will make for easier starting and prevent possible damage to your machine.

In high temperature situations, take the following precautions to prevent possible damage to the machine 1

1

Use the Correct Viscosity Engine Oil

Use the Correct Viscosity Engine Oil See Engine Manufacturer’s Handbook.

See Engine Manufacturer’s Handbook.

2

2

Keep the Battery at Full Charge

3

Fill the Fuel tank at the End of each Working Period

4

Protect the Machine When not in use Put the machine inside a building or cover it with a tarpaulin.

Keep the Hydraulic Oil Cooler Clean Regularly remove dirt and debris from the hydraulic oil cooler, particularly from around the air inlets.

3

Ensure Free Flow of Air to the Engine As the engine on the machine is air cooled it is necessary to ensure that the machine is positioned so as not to restrict the flow of fresh air to the engine.

Note: If the machine is to be used continually at temperatures below 0 ºC consult your JCB Dealer.

HYDRAULIC OUTPUT CONTROL AND CONNECTORS Beaver III, Compact III and Trojan III Hydraulic output control 1 is used to control the flow rate to the tool in use.

Connectors 2 and 3 are used to connect the powerpack to the tool as follows: Connector 2 - Feed (male) Connector 3 - Return (female)

Duopower III Hydraulic output control 1 is used to control the flow rate to the tool connected to the top couplings 4 and 5. This (main) output can be 0 - 20 litres/min or 0 - 40 litres/min, depending on the position of flow rate selector control 3.

Hydraulic output control 2 is used to control the flow rate to the tool connected to the lower coupling 6 and 7. this (secondary) output is 0 - 20 litres/min.

Note: The illustration above shows a Beaver III hydraulic powerpack, however, the layout is similar for the Compact III and Trojan III and Micro machine.

When in the left-hand position, flow rate selector control 3 selects 0 - 20 litres/min from both sets of couplings. When in the right-hand position, the control selects 0 - 40 litres/min from the upper set of couplings.

Connectors 4 and 7 are used to connect the main and secondary circuits to the tool in use as follows: Connector 4 - Main circuit feed (male) Connector 5 - Main circuit return (female) Connector 6 - Secondary circuit feed (female) Connector 7 - Secondary circuit return (male)

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OPERATION

E19

HYDRAULIC POWER PACKS CONNECTING/DISCONNECTING THE HOSES ! CAUTION Ensure that any tools that you are planning to use are compatible with the model of powerpack you are using.

See Specification Section.

Connecting Hoses 1

Prepare the Machine a

Stop the engine.

b Move the output control to mid position.

2

Inspect the Couplers Ensure that all couplers are clean and serviceable. See Maintenance Section.

3

Connect the Hoses a

Attach the return line.

b Attach the feed line.

Note: The connector is locked when the collar is turned away from the ball.

4

Check the Hydraulic Oil Level a

Start the engine and run the machine to fill up the hydraulic circuit.

b Check the hydraulic oil level (see Checking the Hydraulic Oil Level in the Maintenance Section.

Disconnecting Hoses 1

Prepare the Machine a

Stop the engine.

b Move the output control to mid position.

2

Remove the Hoses a

Release the feed line.

b Release the return line.

Note: The connectors are unlocked by moving the collar back on the connect.

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Issue 1

E20

E20

OPERATION HYDRAULIC POWER PACKS CONTENTS

Regular maintenance schedules

E21

Hydraulic couplings

E22

Hydraulic hoses

E22

Cleaning the machine

E22

Checking for damage

E22

Hydraulic circuit

E22

Gaining access to machine components

E26

Fluids, lubricants, capacities and specification

E26

Hydraulic circuit - engine speed and relief valve adjustment Beaver III, Compact III and Trojan III E27 Duopower III

E29

Battery

E32

Fault finding

E33

Note: For engine maintenance see Engine Manufacturer’s Handbook.

9803/1250

Issue 1

E21

MAINTENANCE

E21

HYDRAULIC POWER PACKS REGULAR MAINTENANCE SCHEDULES A poorly maintained machine is a hazard. Doing regular maintenance and lubrication jobs listed in these schedules will help keep the machine in safe working order.

Every 3 Months 1

Do the Daily jobs plus:

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check of hours in use. Do not use a machine which is due for a regular service.

Rectify any defects found during regular maintenance before clearing the machine for use.

2

Clean a

b Engine oil filter.

! WARNING Maintenance must be done only by suitably qualified and competent persons.

Air cleaner elements (see Engine Manufacturer’s Handbook).

3

Change a

Engine oil

Before doing any maintenance, make sure the machine is safe and correctly sited on level ground.

b Hydraulic filter

Daily

c

1

2

Hydraulic oil

Clean

Every 6 Months

Machine generally.

1

Do the Daily and 3-monthly jobs plus:

Check

2

Check

a

Generally for damage.

a

b

Hydraulic fluid level.

b Flow and pressure output.

c

Engine oil level.

d

Hydraulic couplings.

a

e

Hydraulic hoses.

b Hydraulic fluid.

3

Change

c

Note: Check tightness of nuts, bolts, screws and hose fittings after the first days operation and thereafter in accordance with the Maintenance Schedule.

4 Note: The engine oil should be replaced after the first three days operation and thereafter in accordance with the Maintenance Schedules.

tightness of nuts, bolts, screws and hose fittings.

Main hydraulic filter.

Engine oil. (see Engine Manufacturer’s Handbook).

Clean a

Fuel strainer.

b Spark plug - Petrol models only.

5

Check a

Spark plug gap - Petrol models only.

Note: For detailed maintenance procedure, refer to Engine Manufacturer’s Handbook.

9803/1250

Issue 1

E22

MAINTENANCE

E22

HYDRAULIC POWER PACKS HYDRAULIC COUPLINGS The JCB Hydraulic Powerpacks are fitted with quick-release hydraulic couplings to allow the operator to remove and install attachments swiftly and efficiently. The couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly.

The following guidelines should be followed:

6

When fitting adaptors to the coupling, always clamp using the hexagon provided. Do not attempt to clamp or use an adjustable spanner on the sleeve as this will distort it.

7

Never try to turn the sleeve when disconnected as the locking ball will jam underneath the sleeve and destroy the coupling.

8

If a coupling sticks, which may occur if dirt is present through neglect, then only a hide or rubber hammer should be used to aid disconnection.

9

Care must be take to ensure that the faces of the coupling do not become damaged as this can prevent proper connection and disconnection or damage the seals and cause leakage.

1

Before making a connection, wipe the two faces of the coupling and ensure that they are clean.

2

When disconnecting, ensure that the outside sleeve is pulled back.

3

When using a new coupling, connect and disconnect several times to ‘work’ the P.T.F.E. seals. This will prevent the seal ‘sticking’.

4

Do not attempt to reconnect using a damaged halfcoupling as this will destroy the seals and necessitate replacing both halves.

10

Do not attempt to strip down and service a damaged coupling as there are not serviceable parts. Always replace damaged couplings.

Do not leave the coupling where it can be run over or otherwise crushed as this can distort the sleeve and make correct connection and disconnection impossible.

11

Only use couplings as supplied by JCB since the fitting of inferior makes can cause damage and will invalidate any warranty.

12

Ensure that the hydraulic filter has been properly maintained. This will prevent oil contamination from damaging the couplings.

5

HYDRAULIC HOSES Note: Hoses displaying any of the following damage must not be used and should be replaced immediately.

1

End fitting damaged or leaking.

2

Outer covering chafed or cut and wire re-inforcing exposed.

3

Outer covering ballooning locally.

4

Evidence of kinking or crushing on flexible part of hose.

5

Armouring embedded in outer cover.

6

End fittings displaced.

7

Chafing of hoses.

Note: Hoses must not be twisted. Replace any broken hose straps to avoid damaging hoses.

CLEANING THE MACHINE Clean the machine using water and/or steam. Do not allow mud to build up on the engine. Make sure that the air inlets on the hydraulic cooler are not clogged.

9803/1250

CHECKING FOR DAMAGE 1

Check framework for damage.

2

Check machine generally for obvious signs of damage.

3

Ensure that all safety and operating decals are undamaged and legible.

Issue 1

E23

MAINTENANCE

E23

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT Checking the Hydraulic Fluid Level 1

Prepare the Machine Position the machine on level ground. Switch off the engine and allow it to cool down.

2

Check the Hydraulic Fluid Level a

Check the hydraulic fluid level using sight gauge A.

b If necessary top up the hydraulic fluid through filler B. Note: Use only the recommended hydraulic fluid.

Changing the Hydraulic Fluid Note: The illustration shown is for a typical machine. Whilst the layout of each powerpack may vary slightly, the location of the sight gauge A, filler cap B and drain plug C is the same.

1

Prepare the Machine Position the machine on level ground. Switch off the engine and allow it to cool down.

2

Drain the Hydraulic Fluid a

Place a container of a suitable size below the tank drain plug C to catch the fluid.

b Remove drain plug C and filler cap B and allow fluid to drain out.

3

Replace the Hydraulic Fluid a

Clean and refit drain plug C.

b Pour fluid through filler until it reaches the required level on sight gauge A. c

Refit filler cap B.

Note: Use only the recommended hydraulic fluid.

9803/1250

Issue 1

E24

MAINTENANCE

E24

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT (continued) Changing the Main Hydraulic Filter ! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

Note: On Duopower III powerpacks, the hydraulic filter is mounted on top of the hydraulic tank.

1

Prepare the Machine Position the machine on level ground. Switch off the engine and allow it to cool down.

Place a container of suitable size beneath the filter to catch any spilt fluid.

2

Remove Used Filter a

Remove the three bolts A securing the lid to hydraulic filter housing B, and remove the lid.

b Lift out and dispose of the used filter.

! WARNING There may be limited fluid spillage when the filter is removed. Clean any spillage immediately and dispose of materials in accordance with current regulations.

3

Fit New Filter a

Push the new element C firmly into place in the filter housing B.

b Refit the lid on the filter housing B, ensuring that spring clip D located between spigots E. Secure with the three bolts A. 4

Check the Hydraulic Fluid Level Check the hydraulic fluid level, see Checking the Hydraulic Fluid Level.

9803/1250

Issue 1

E25

MAINTENANCE

E25

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT (continued) Cleaning the Oil Cooler The oil cooler fins may be cleaned using low pressure compressed air. Do not attempt to clean using a wire brush as this could damage the fins.

Replacing the Oil Cooler 1

Remove the hoses

! WARNING There may be limited oil spillage when the standpipes are removed. Clean any spillage immediately and dispose of materials in accordance with current regulations. a 2

Loosen the jubilee clips and remove the hoses A.

Remove the Cooler a

Undo the eight bolts B and remove the guard C.

b Remove and dispose of the damaged cooler.

3

Reassemble a

Clean the guard and refit it and the new cooler.

b Push the cooler up to the fan housing and ensure an airtight fit. Replace and tighten the eight bolts B. 4

Replace the Hoses a

5

Apply sealant to the threads and cores on the hoses.

Refit the hoses and tighten the fittings using two spanners.

Run and Test a

Run the machine and top up hydraulic fluid as necessary.

b Ensure that the machine functions correctly.

Note: Ensure that all fittings are airtight, allowing no air to be sucked into the hydraulic fluid circuit.

9803/1250

Issue 1

E26

MAINTENANCE

E26

HYDRAULIC POWER PACKS GAINING ACCESS TO MACHINE COMPONENTS To facilitate easier maintenance, the tubular frame is fitted with hinge bolts. The frame may be moved to afford ready access to the machine components in the following manner: 1

Remove Securing Clips Remove and retain securing clips A.

2

Move the Frame Lift the tubular frame out of the way of the machine components by hinging it on bolts B.

Note: It is important that after maintenance, the tubular frame is restored to its operating position and that the clips A are securely fitted.

Note: When the machine is to be lifted using the balanced lifting point C, it is important to ensure that the clips A are in place and securely fitted.

FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATION ITEM

CAPACITY Litres (UK gal)

FLUID/LUBRICANT

Engine (Oil)

Refer to Manufacturer’s handbook as supplied.

Refer to Manufacturer’s handbook as supplied.

3.6 (0.79) 6.0 (1.32) 6.5 (1.43) 3.5 (0.77) 5.5 (1.45) 4.3 (0.95) 6.0 (1.32) 8.5 (1.87)

Unleaded petrol Unleaded petrol Unleaded petrol Refer to Manufacturer’s Handbook Refer to Manufacturer’s Handbook Refer to Manufacturer’s Handbook Refer to Manufacturer’s Handbook Refer to Manufacturer’s Handbook

Micro

3.3 (0.72)

Compact III

4.0 (1.09)

Beaver III

7.0 (1.53)

Trojan III

7.0 (1.53)

Duopower III

7.0 (1.53)

JCB Hydraulic Oil HP32 Part No. 4002/1000 JCB Hydraulic Oil HP32 Part No. 4002/1000 JCB Hydraulic Oil HP32 Part No. 4002/1000 JCB Hydraulic Oil HP32 Part No. 4002/1000 JCB Hydraulic Oil HP32 Part No. 4002/1000

Fuel Tanks: Honda GX160 Honda GX240, GX340, GX390 Suzuki V270 Yanmar L70E Yanmar L100E Lombardini 15LD Robin DY 35D Briggs & Stratton Vanguard Hydraulic Fluid Tanks:

9803/1250

Issue 1

E27

MAINTENANCE

E27

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT Beaver III, Compact III and Trojan III ! WARNING Maintenance must be done by suitable qualified and competent persons.

The engine speed of the powerpack is controlled by a small ram which is activated by the hydraulic circuit pressure. As the hydraulic pressure rises, the ram extends pushing the throttle to increase the engine speed to a preset level.

To enable these adjustments to be carried out the following piece of test equipment is required: Hydraulic Flow and Pressure Tester (JCB Attachments Part number 5073) Note: To gain access to the relief valve it is necessary to move the tubular frame.

1

Connect the Test Equipment Connect the hydraulic flow and pressure tester to the machine as shown

2

Start the Engine Start the engine (see Operation Section) and allow the machine at least 5 minutes to warm up with the test equipment adjusted to read approximately 55 bar (800 lbf/in2).

3

Check the Flow Rate a

Adjust the test equipment shut-off valve A until the following pressure reading is registered on test gauge B. Compact III machines - 69 bar (1000 lbf/in2) Beaver III machines - 90 bar (1300 lbf/in2) Trojan III machines - 90 bar (1300 lbf/in2)

b Read off the flow rate as indicated on the flow gauge C. c

If the correct flow rate is indicated go to Step 7, if incorrect go to Step 4.

Note: The correct flow rates depend on the machine model as below: Category C models - 20 litres/min Category D models - 30 litres/min Category E models - 40 litres/min

! WARNING Increasing the engine speed beyond 3600 rev/min will overspeed tools which could cause failure and operator injury.

Note: Overspeeding of tools could also invalidate the warranty.

9803/1250

Issue 1

E28

MAINTENANCE

E28

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued) Beaver III, Compact III and Trojan III (continued) 4

b Read off the flow rate on the flow gauge C. Note: If the correct flow rate is not indicated go to Step 7. If still incorrect go to Step 6.

Check Relief Valve Setting 6 a

Close off the shut-off valve A gradually until a readying of no greater than the following is obtained: Compact III machines - 86 bar (1250 lbf/in2) Beaver III machines - 138 bar (2000 lbf/in2) Trojan III machines - 138 bar (2000 lbf/in2)

b Remove the relief valve adjustment seal cap D. c

a

Loosen the nuts G on the throttle ram piston rod.

b Adjust the barrel nut H up to increase the engine speed.

Note: The test gauge B must be continually checked and the shut-off valve A adjusted to maintain the following pressure during speed adjustment:

Loosen adjusting screw locking nut E.

Compact III machines - 69 bar (1000 lbf/in2) Beaver III machines - 90 bar (1300 lbf/in2) Trojan III machines - 90 bar (1300 lbf/in2)

! CAUTION The pressure settings quoted above must not be exceeded.

The pressure setting may now be adjusted by means of adjusting screw F.

Adjust the Flow Rate

! CAUTION Do not exceed the rated maximum of 20 litres/min, or 30 litres/min at 3600 rev/min (depending on model).

7

Check the Throttle Return Open the shut-off valve A and ensure that the throttle ram has fully returned into its cylinder by pushing the end of the piston rod.

8

Carry out a Functional Check Finally, check that the machine operates satisfactorily by connecting and operating a tool.

Note: The illustration above shows that hydraulic ram as mounted on petrol engine models. The ram is mounted differently on diesel engine models but the adjustments are are same.

5

Re-check the Flow a

Readjust the shut-off valve A until the following pressure reading is again registered on the test gauge B.

Ensure that all controls and adjusters are fully secured and that all covers are replaced when adjustments are completed.

Compact III machines - 69 bar (1000 lbf/in2) Beaver III machines - 90 bar (1300 lbf/in2) Trojan III machines - 138 bar (2000 lbf/in2)

9803/1250

Issue 1

E29

MAINTENANCE

E29

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued) Duopower III ! WARNING Maintenance must be done by suitable qualified and competent persons.

The engine speed is preset and should be 3600 rev/min loaded.

! WARNING Increasing the engine speed beyond 3600 rev/min will overspeed tools which could cause failure and operator injury.

Note: Overspeeding of tools could also invalidate the warranty.

To enable these adjustment to be carried out the following piece of test equipment is required: Hydraulic Flow and Pressure Tester (JCB Attachments Part Number 5073) Note: To gain access to the relief valve it is necessary to move the tubular frame.

1

Connect the Test Equipment Connect the hydraulic flow and pressure tester to the secondary hydraulic circuit (lower set of couplings) as shown. Ensure that both control levers are in the OFF position ( 0 litres/min) and that the flow rate selector lever is in the 20 litres/min position (fully left).

2

Start the Engine Start the engine (see Operations Section) and set the (lower) secondary circuit control lever to the ON position. Allow the machine at least 5 minutes to warm up with the test equipment adjusted to read approximately 55 bar (800 lbf/in).

3

Check the Secondary Circuit Flow Rate a

Adjust the test equipment shut-off valve A until until a pressure reading of 90 bar (1300 lbf/in2) is registered on test gauge B.

b Read off the flow rate as indicated on the flow gauge C. This should be 20 litres/min.

9803/1250

Issue 1

E30

MAINTENANCE

E30

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued) Duopower III (continued) 4

Check the Secondary Relief Valve Setting a

Gradually close shut-off valve A, the reading should not exceed 138 bar (2000 lbf/in2).

b If the pressure is incorrect, remove the relief valve adjustment screw seal cap D. c

Loosen adjusting screw lock nut E.

! WARNING The pressure setting must not exceed 138 bar (2000 lbf/in2). d Adjust the pressure setting using screw F. 5

Recheck the Flow a

Re-adjust the shut-off valve A until a pressure reading of 90 bar (1300 lbf/in2) is again shown on test gauge B.

b Read off the flow rate ad indicated on the flow gauge C. This should be 20m litres/min.

Note: If the flow rate is now incorrect, consult your JCB Attachments Distributor.

6

Reconnect the Test Equipment Stop the engine and connect the hydraulic flow and pressure test equipment to the main hydraulic circuit (upper set of couplings).

7

Start the Engine Start the engine and set the (upper) main circuit control lever to the ON position. Allow the machine to warm up if not already warm, with the test equipment adjusted to rear 55 bar (800 lbf/in2).

8

Check the Main Circuit Flow Rate a

Adjust the test equipment shut-off valve A until a pressure gauge reading of 90 bar (1300 lbf/in2) is registered on test gauge B.

b Read off the flow rate as indicated on the flow gauge C. This should be 20 litres/min.

9803/1250

Issue 1

E31

MAINTENANCE

E31

HYDRAULIC POWER PACKS HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued) Duopower III (continued) 9

Check the Main Relief Valve Setting a

Gradually close shut-off valve A, the reading should not exceed 138 bar (2000 lbf/in2). If the pressure is correct, go to paragraph 11.

b If the pressure is incorrect, remove the relief valve adjustment screw seal cap D. c

Loosen adjusting screw lock nut E.

! WARNING The pressure setting must not exceed 138 bar (2000 lbf/in2). d Adjust the pressure setting by means of screw F. 10

Recheck the Flow a

Re-adjust the shut-off valve A until a pressure reading of 90 bar 1300 lbf/in2) is again shown on test gauge B.

b Read off the flow rate on flow gauge C. This should be 20 litres/min. If the flow rate is now incorrect, consult your JCB Dealer.

11

Check the Main Circuit Flow rate - 40 litres/min a

Set the flow rate selector lever to 40 litres/min (fully right). Fully select the (lower) secondary circuit control lever to 20 litres/min and adjust the test equipment shut-off valve A until a pressure reading of 90 bar (1300 lbf/in2) is registered on test gauge B.

b Read off the flow rate as indicated on the flow gauge C. This should be between 38 and 40 litres/min. If the flow rate is incorrect, consult your JCB Dealer.

9803/1250

Issue 1

E32

MAINTENANCE

E32

HYDRAULIC POWER PACKS BATTERY ! WARNING

! WARNING

Battery electrolyte contains sulphuric acid. If can burn you if it touches your skin or eyes. Wear safety glasses and handle the batteries carefully to prevent spillage.

Set all switches to OFF before disconnecting and connecting the batteries. When disconnecting the batteries, take off the negative (-) lead first. When reconnecting the batteries fit the positive (+) lead first.

! WARNING

! WARNING

Keep metallic items (watches, rings, zippers, etc) away from the battery terminals. Such items could short the terminals and burn you..

Recharge the batteries away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the batteries. When you have installed the batteries in the machine, wait five minutes before connecting them up.

! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the batteries. Keep the batteries away from sparks and naked flames.

! WARNING Do not top up the battery with acid. The electrolyte could boil out and burn you.

Checking the Electrolyte Level

First Aid - Electrolyte

1

Prepare the Machine

Eyes

Position the machine on level ground. Switch off the engine and allow it to cool down.

Flush with water for 15 minutes. Get medical help immediately.

Remove the Battery covers

Skin

Unscrew and remove battery covers.

Flush with water. remove affected clothing.

Check the Level

If Swallowed

a

Do not induce vomiting. Drink large quantities of water or milk. then drink Milk of Magnesia, beaten egg or vegetable oil

2

3

Look at the level in each cell. The electrolyte should be 6 mm (1/4in) above the plates.

b Top up if necessary with distilled or de-ionised water.

4

Refit the Battery Covers Refit battery covers.

9803/1250

Issue 1

E33

MAINTENANCE

E33

HYDRAULIC POWER PACKS FAULT FINDING ! WARNING Maintenance must be done only by suitably qualified and competent persons.

Symptom

Possible Fault

Remedy

Engine does not start

No fuel Fuel On/Off switch OFF Rotary switch OFF Low engine oil Choke incorrectly set for engine Temperature Spark plug fouled or wet Loose or broken plug lead Ignition fault

Fill tank Turn ON Turn ON Replenish engine sump If cold set fully ON. If warm set ON Clean plug Refit or renew, check for spark at plug Check

Poor powerpack performance

Powerpack output incorrect

Check powerpack output with flow and pressure tester Check calibration Check calibration Repair or replace Replace Remove and clean Repair or replace Replace Renew ‘O’ rings, coat valve with grease and refit.

Consult tool Handbook

Low relief valve setting Poor engine speed adjustment Sticking or damaged throttle ram Damaged hoses or couplers Blocked suction strainer Worn or damaged hydraulic pump Relief valve worn Damaged ‘O’ rings on relief valve Faulty tool Engine speed does not idle when tool not operating

Broken ram return spring High system back pressure caused by hoses over 8 m or damaged hoses or couplers Unit not fully warmed up

Fit new spring Check system

Allow to warm up (operate tool(s) continuously)

Tool runs hot

Blocked cooler air intake Poor powerpack ventilation High back pressure Damage to cooler fan Low relief valve setting

Cleat intake Re-site powerpack Check system Check for blade damage Reset or replace

Unable to connect hoses or tools

Pressure lock in system

Connector damaged

Connect return line first, vent system using control valve mid position, vent pressure from hose by unscrewing connector.

Replace connector

Leak of air into suction circuit, tanks, cooler or pump

Tighten fittings, check cooler for damage.

Oil foams out of breather

9803/1250

Issue 1

F1

SPECIFICATION

F1

CONTENTS

9803/1250

Static dimensions

F2

Engine types and powerpack weights

F2

Flow rates and hose length

F3

New developments

F4

Issue 1

F2

SPECIFICATION

F2

STATIC DIMENSIONS

Compact III

Beaver III

Trojan III/Doupowe III

Micro

Height (A)

-

505 mm (19.9 in)

610 mm (24.0 in)

735 mm (28.9 in)

480 mm (18.9 in)

Width (B)

-

495 mm (19.5 in)

530 mm (21.0 in)

590 mm (23.2 in)

434 mm (17.08 in)

Length (C) -

630 mm (24.8 in)

720 mm (28.0 in)

812 mm (32.0 in)

626 mm (24.64 in)

Weight

50 kg (110 lb)

75 kg (165 lb) - Honda 99 kg (218 lb) - Lombardini

99 kg (218 lb)

48.5 kg (107 lb)

-

ENGINE TYPES AND POWERPACK WEIGHTS Powerpack

Model

Fuel

Starting

Engine

Performance

Compact III

929/20000

Petrol

Recoil

Honda CG160

5.3 HP (4 kW)

Beaver III

929/16400 929/16600 929/16100 929/17200 929/18000

Petrol Petrol Diesel Diesel Diesel

Recoil Recoil Recoil Recoil Electric

Honda GX240 Suzuki V270 Yanmar L70E Lombardini 15LD Lombardini 15LD

8 HP (6 kW) 9 HP (6.7 kW) 7 HP 95.2 kW) 6.7 Hp (4.9 kW) 6.7 HP (4.9 kW)

Trojan III

929/32200 929/32300 929/32000 929/32100 929/32400 929/32500 929/32600 929/32700

Diesel Diesel Petrol Petrol Petrol Petrol Diesel Diesel

Recoil Electric Recoil Electric Recoil Electric Recoil Electric

Robin DY 35D Robin DY 35D Honda GX340 Honda GX340 Honda GX390 Honda GX390 Yanmar L100AE-D Yanmar L100AE-DE

8 HP (6 kW) 8 HP (6 kW) 11 Hp (8.2 kW) 11 Hp (8.2 kW) 13 HP (9.7 kW) 13 Hp (9.7 kW) 10 HP (7.5 kW) 10 HP (7.5 kW)

Duopower

929/32800 929/32900

Petrol Petrol

Recoil Electric

Briggs & Stratton Vanguard Briggs & Stratton Vanguard

18 HP (13.4 kW) 18 HP (13.4 kW)

Micro

929/92200

Petrol

Recoil

Honda GX160

5.3 HP (4 kW)

9803/1250

Issue 1

F3

SPECIFICATION

F3

FLOW RATES AND HOSE LENGTH

Flow Rates The European Hydraulic Tool Manufacturers Association (E.H.T.M.A.) of which JCB is a member, had catergorised Hydraulic Powerpacks and tools in terms or flow rate and working pressures.

The Compact III, Beaver III, Trojan III and Micro Series of Hydraulic Powrpack models are categorised by the E.H.T.M.A. as below.

Model

Flow Rate (litres/min)

Max. Pressure (bar)

E.H.T.M.A. Cat.

Micro

0 - 20

138

C

Compact III

0 - 20

69

C

Beaver III

0 - 20

138

C

Trojan III

0 - 20 0 - 30

138 138

C D

Duopower III

0 -20/0 - 40

150

C/E

Note: All JCB Hydraulic Powerpacks are clearly marked with their E.H.T.M.A. category. It is important that any tool used with the powerpack is of a compatible category, if in any doubt consult your JCB Dealer.

Hose Length 1

Normally 5 metres of Siamesed hose is to be used for Compact III and Micro machines, and 7 metres for Beaver III, Trojan III and Duopower machines.

2

In normal temperatures (0 - 40 ยบC) the maximum hose length should not exceed 25 metres.

9803/1250

Issue 1

F4

SPECIFICATION

F4

NEW DEVELOPMENTS

As part of their policy of continuing development JCB Attachments have produced a series of decals designed with safety, ease of operation and maintenance in mind. These can normally be found in 9800/9040 Issue 4, but it has been decided to include them in this manual for the operators information.

You should always check the serial number of your Powerpack and speak with your JCB Dealer of JCB Attachments if in any doubt.

! WARNING You must understand and follow the instructions in the manual. If you are unsure about anything, ask your JCB Dealer or employer. Do not guess, or you and others could be killed or seriously injured.s

9803/1250

Issue 1

F5

SPECIFICATION

F5

NEW DEVELOPMENTS (continued)

STOP

x2

START

STOP

START

1021

Beaver - Yanmar

Fig. 1 x2

1022

Beaver - Lombardini

x2

1023

Fig. 2

Beeaver & Compact - Honda

1 x2

3

2

1

Trojan - Honda 1034

STOP

x2

Fig. 2A

START

STOP

START

1025

Trojan - Yanmar

Duopower

1037

Micro 9803/1250

Issue 1

F6

SPECIFICATION

F6

NEW DEVELOPMENTS (continued) STOP

x2

START

1027

Beaver - Yanmar

x2

STOP

1028

Beaver - Lombardini

x2

Beeaver & Compact - Honda

102

x2

1031

Trojan - Honda

STOP

x2

START

1032

Trojan - Yanmar

Duopower

1038

Micro

Fig. 4

9803/1250

Issue 1

F7

SPECIFICATION

F7

NEW DEVELOPMENTS (continued)

Fig. 5

Fig. 6

Fig. 7

Fig. 8

B

A

Fig. 10

Fig. 9

B

A 1036

Fig. 10a

Fig. 11 9803/1250

1035

Fig. 10b

Fig. 12 Issue 1

F8

SPECIFICATION

F8

NEW DEVELOPMENTS (continued)

Introduction Connecting Hoses (Figs. 1, 2) The following powerpacks are covered by this handbook: Beaver III, Compact III, Trojan III, Duopower, Micro.

To operate the JCB range of powerpacks efficiently and safely you must know the powerpack and have the skill to use it. If you are a new operator, you should become trained in the skills of using a powerpack before trying to work with it.

It is assumed that personnel carrying out maintenance have at least a sound knowledge of workshop practice, safety procedures and general techniques associated with the repair of hydraulic equipment. it is expected that components will 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.

Serial numbers are stamped on a spacer plate between the engine and the hydraulic tank or chassis on the Micro.

It is important to quote the serial number when making repairs or ordering parts.

Safety Decals Keep all decals clean and readable. Replace lost or damaged decals.

Before Operating the Machine z

Check for Cleanliness.

z

Check for Damage.

z

Check for Leaks.

z

Make sure the fuel filler cap is tightly closed.

z

Check Hydraulic Oil Level.

z

Ensure the machine is positioned safely.

z

z

Ensure that all hydraulic couplings are fully serviceable. Refer to Hydraulic Couplings.

Ensure that any hydraulic tools you are planning to use are compatible with the model of the machine you are using.

Check Engine Oil Level

z

Check the Fuel

z

! Never refuel with the engine running.

Operating in Low Temperatures z z

Use the Correct Viscosity Engine Oil See Engine Manufacturer's Handbook.

Keep the Battery at Full Charge

z

Fill the Fuel Tank at the End of each Working Period

z

Protect the Machine When not in Use

Note: If the machine is to be used continually at temperatures below 0°C consult your JCB Dealer.

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a Stop the engine. b Move the Output control to mid position or off position. c Attach Return line. d Attach Feed line.

Note: The connector is locked when the collar is turned away from the ball. e Start the engine and run the machine to fill up the hydraulic circuit. f Check the hydraulic oil level.

Hydraulic Output Control and Connectors BEAVER III, COMPACT III AND TROJAN III (Fig. 1) MICRO (Fig. 2a) Hydraulic output control (1) is used to control the flow rate to the tool in use.

Connectors (2) and (3) are used to connect the powerpack to the tool as follows: Connector (2) - Feed (male).

Connector (3) - Return (female).

DUOPOWER III (Fig. 2) Hydraulic output control (1) is used to control the flow rate to the tool connected to the top couplings (4) and (5). This (main) output can be 0-20 litres/min or 0-40 litres/min depending on the position of flow rate selector control (3).

Hydraulic output control (2) is used to control the flow rate to the tool connected to the lower couplings (6) and (7). This (secondary) output is 0-20 litres/min. When in the left-hand position, flow rate selector control (3) selects 0-20 litres/min from both sets of couplings. When in the right-hand position, the control selects 0-40 litres/min from the upper set of couplings. Connectors (4) to (7) are used to connect the main and secondary circuits to the tool in use as follows: Connector (4) - Main circuit feed (male) Connector (5) - Main circuit return (female) Connector (6) - Secondary circuit return (female) Connector (7) - Secondary circuit feed (male)

Starting/Stopping (Figs. 3/4) Notes: Honda GX160, GX240, GX340 and GX390 Engines: The engines are fitted with an Oil Alert system which is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. The oil alert system will automatically shut down the engine before the oil in the crankcase can fall below a safe limit.

If the Oil Alert system has shut down the engine then the Oil Alert indicator will flash when you attempt to restart the engine.

Yanmar L70E and L100E Engines: In cold weather if your engine is hard to start, remove rubber plug and add 2 c.c. of engine oil before starting (Fig. 5).

After starting, allow the engine to idle for a few minutes then slacken the engine speed control (Fig. 6).

Lombardini 15LD315 Engines: After starting, allow the engine to idle for a few minutes then slacken wingnut (Fig. 7).

Issue 1

F9

F9

SPECIFICATION NEW DEVELOPMENTS (continued)

Starting/Stopping (Figs. 3/4) (continued) Temperature Idling Time below -20°C -20°C to -10°C -10°C to 5°C above 5°C

5 minutes 2 minutes 1 minute 20 seconds

Recoil Start Models: Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage.

Lombardini Recoil Start Models: Pull the starter grip lightly until resistance is felt, then pull briskly.

Yanmar Recoil Start Models: Use the starter grip to turn the engine over until compression is reached, then push down the compressor control B (Fig. 12).

Electric Start Models: Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again.

Service Schedules

z Engine oil filter.

Change z Engine oil z

Hydraulic filter

z

Hydraulic oil

Every 100 hours or 6 Months Do the Daily and 3-monthly jobs plus: Check: z Tightness of nuts, bolts, screws and hose fittings. z

Change z Main hydraulic filter. z

Hydraulic fluid.

z

Engine oil.

Handbook).

! WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance, make sure the machine is safe and correctly sited on level ground.

Check z Generally for damage. z

Hydraulic fluid level.

z

Engine oil level.

z

Hydraulic couplings.

z

Hydraulic hoses.

Every 50 hours or 3 Months Do the Daily jobs plus: Clean z Air cleaner elements.

(See Engine Manufacturer's Handbook).

9803/1250

Manufacturer's

Spark plug - Petrol models only.

Note: For detailed maintenance procedure, refer to Engine Manufacturer's Handbook.

Checking the Hydraulic Fluid Level (Fig. 8, 10a) 1

Prepare the Machine Position the machine on level ground. Switch off the engine and allow it to cool down.

Check the Hydraulic Fluid Level a Check the hydraulic fluid level using sight gauge A. b If necessary top up the hydraulic fluid through filler B.

Note: Use only the recommended hydraulic fluid.

Changing the Hydraulic Fluid (Fig. 8) Note: The illustration shown is for a typical machine.

1 2

Note: Check tightness of nuts, bolts, screws and hose fittings after the first days operation and thereafter in accordance with Service Schedules.

Note: The engine oil should be replaced after the first three days operation and thereafter in accordance with the Maintenance Schedules.

Engine

Check z Spark plug gap - Petrol models only.

2 Daily z Clean machine generally. Clean the machine using water and/or steam. Do not allow mud to build up on the engine. Make sure that the air inlets on the hydraulic cooler are not clogged.

(See

Clean z Fuel strainer. z

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check of hours in use. Do not use a machine which is due for a regular service.

Rectify any defects found during regular maintenance before clearing the machine for use.

Flow and pressure output.

3

Position the machine on level ground. Switch off the engine and allow it to cool down.

Drain the Hydraulic Fluid a Place a container of a suitable size below the tank drain plug C to catch the fluid (Beaver, Compact, Trojan 2, Duopower only). b Remove drain plug C and filler cap B and allow fluid to drain out.

Replace the Hydraulic Fluid. a Clean and refit drain plug C. b Pour fluid through filler until it reaches the required level on sight gauge A. c Refit filler cap B.

Note: Use only the recommended hydraulic fluid.

Issue 1

F10

F10

SPECIFICATION NEW DEVELOPMENTS (continued)

Changing the Main Hydraulic Filter (Beaver, Compact, Trojan2, Duopower ) (Figs. 9/10)

! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

! WARNING There may be limited fluid spillage when the filter is removed. Clean any spillage immediately and dispose of materials in accordance with current regulations.

2

Note: It is important that after maintenance, the tubular frame is restored to its operating position and that the clips A are securely fitted.

Note: When the machine is to be lifted using the balanced lifting point C, it is important to ensure that the clips A are in place and securely fitted.

Checking the Electrolyte Level 1

Note: On Duopower III powerpacks, the hydraulic filter is mounted on top of the hydraulic tank.

2 3

1

4 5

2 3 4 5 6

7

Position the machine on level ground. Switch off the engine and allow it to cool down.

Place a container of suitable size beneath the filter to catch any spilt fluid.

Remove the three bolts A securing the lid to hydraulic filter housing B, and remove the lid.

Lift out and dispose of the used filter.

Push the new element C firmly into place in the filter housing B. Refit the lid on the filter housing B, ensuring that spring clip D locates between spigots E. Secure with the three bolts A. Check the hydraulic fluid level, see Checking the Hydraulic Fluid Level.

Lift the tubular frame out of the way of the machine components by hinging it on bolts B.

Position the machine on level ground. Switch off the engine and allow it to cool down.

Unscrew and remove battery covers.

Look at the level in each cell. The electrolyte should be 6 mm (1/4 in.) above the plates.

Top up if necessary with distilled or de-ionised water.

Refit battery covers.

! WARNING Battery electrolyte contain sulphuric acid. It can burn you if it touches your skin or eyes. Wear safety glasses and handle the battery carefully to prevent spillage.

(Micro) (Fig. 10b) 1 2 3 4 5

Position the machine on level ground. Switch off the engine and allow it to cool down.

Place a container of suitable size beneath the filter to catch any spilt fluid.

Remove oil filter canister with oil filter wrench or hand.

Replace with a new oil filter canister.

Check the hydraulic fluid level, see Checking the Hydraulic Fluid Level.

Cleaning the Cooler The oil cooler fins may be cleaned using low pressure compressed air. Do not attempt to clean using a wire brush as this could damage the fins.

Gaining Access to Machine Components (Fig. 11) To facilitate easier maintenance, the tubular frame is fitted with hinge bolts. The frame may be moved to afford ready access to the machine components in the following manner: 1

Remove and retain securing clips A.

Note: Access to Micro is achieved by removing the four bolts in the tubular frame.

9803/1250

Issue 1

F11

SPECIFICATION

F11

NEW DEVELOPMENTS (continued)

Average Noise Levels (Lpa) Model

Engine

at 1 metre

at 4 metres

at 7 metres

Micro Compact III Beaver III

Honda GX160 Honda GX160 Honda GX240 Suzuki V270 YanmarL70E Lombardini 15LD Honda GX340 Honda GX390 Robin DY 35D Yanmar L100E Briggs & Stratton Vanguard

89.4 dB(A) 92.9 dB(A) 88.6 dB(A) 90.8 dB(A) 91.7 dB(A) 93.9 dB(A) 92.9 dB(A) 93.4 dB(A) 96.6 dB(A) 97.6 dB(A)

81.7 dB(A) 85.5 dB(A) 82.8 dB(A) 84.1 dB(A) 85.9 dB(A) 88.0 dB(A) 85.5 dB(A) 86.8 dB(A) 90.5 dB(A) 88.8 dB(A)

77.6 dB(A) 81.6 dB(A) 79.2 dB(A) 79.7 dB(A) 81.4 dB(A) 82.8 dB(A) 81.6 dB(A) 82.1 dB(A) 85.9 dB(A) 75.9 dB(A)

94.6 dB(A)

85.5 dB(A)

82.0 dB(A)

Trojan III

Duopower III

Fluids & Capacities ITEM Engine (Oil)

Fuel Tanks: Honda GX160 Honda GX240, GX340, GX390 Yanmar L70E Yanmar L100E Lombardini 15LD Briggs & Stratton Vanguard

CAPACITY Litres (Gal)

FLUID/LUBRICANT

Refer to Manufacturer's Handbook as supplied.

Refer to Manufacturer's Handbook as supplied.

3.6 6.0 3.5 5.5 4.3 8.5

(0.79) (1.32) (0.77) (1.45) (0.95) (1.87)

Unleaded petrol Unleaded petrol Refer to Manufacturer's Handbook Refer to Manufacturer's Handbook Refer to Manufacturer's Handbook Refer to Manufacturer's Handbook

3.3 4.0 7.0 7.0 7.0

(0.72) (1.09) (1.53) (1.53) (1.53)

Hydraulic Fluid Tanks: Micro Compact III Beaver III Trojan III Duopower III

9803/1250

JCB Hydraulic Oil HP 32 Part No. 4002/1000

Issue 1

JCB ATTACHMENTS The Warranty becomes effective in accordance with the terms shown below for a period of twelve months from the date of purchase by the original user.

IMPORTANT Read the JCB Attachments Owner’s Manual BEFORE operating the Attachment.

The use of non-approved lubricants/hydraulic fluid will invalidate the Warranty.

WARRANTY POLICY This JCB Attachments is guaranteed against defects in workmanship and/or material when properly maintained and operated under conditions laid down in the WARRANTY AND PROCEDURE. Should any defect develop in the unit during the warranty period you are advised to contact your JCB Dealer. In the event of the fault being attributed to bad workmanship or defective manufacture or material, the dealer will take the appropriate warranty action. (The Manufacturer’s Warranty does not apply to proprietary or other components not of its manufacture used with the equipment.)

For conditions of warranty, please see overleaf.

WARRANTY AND PROCEDURE Examination of the goods has been made by, or on behalf of the Purchaser and no warranty condition, description or representation on the part of the Manufacturer is given or is to be implied or has been given or is to be implied from anything said or written in the negotiations between the parties or their representatives beyond those mentioned below. Any statutory or other warranty condition, description or representation expressed or implied as to the state quality of fitness for any purpose of the goods is hereby expressly excluded.

In lieu thereof the Manufacturer undertakes to make good by repair or replacement at its option free of all charges other than labour costs any defects in the goods arising, in the Manufacturer’s opinion, from faulty design, materials or workmanship which shall become apparent within a period of twelve months in the case of units and three months in the case of parts or equipment from the date or receipt of the goods at the termination of which periods all liability on the Manufacturer’s part ceases. Provided always and the above warranty is subject to the following conditions:

a The Manufacturer’s liability extends only to repair or replacement and it accepts no liability for any consequential or other loss, damage or injury resulting directly or indirectly from any defect in the goods.

e In the event of the rejection by the Manufacturer of any claim, the part or parts returned will be destroyed unless specific instructions to the contrary were given when the part or parts were returned.

h This warranty should be construed as strictly limited in its application to new JCB Products and if the goods shall change hands during the period of this warranty shall cease to have any effect.

b The Manufacturer’s warranty does not extend to failures, defects or damage attributable to wear and tear, improper adjustment, neglect, alteration of specification, or accident.

f The registration card must be returned to the Manufacturer within seven days of the receipt of any new Attachment.

i The Manufacturer accepts no responsibility for damage by fires or accident of any kind to any goods returned to it under the terms of this warranty nor does the Manufacturer accept responsibility for any accident occurring to such goods whilst on the premises.

c Defective parts must be returned to the Main Dealer when requested together with full particulars of the defects, the serial number, the hours worked and the date the unit was supplied to the Main Dealer who will claim on your behalf. d The Manufacturer’s warranty does not extend to proprietary or other components not of its manufacture, but will as far as possible pass to the Purchaser the benefits of any guarantee given to the Manufacturer in respect of such components.

g No claim will be considered if other than genuine parts manufactured by the Manufacturer or to its order and listed in its catalogue are used or if other than JCB ‘Special’ Hydraulic Fluid is used where specified.

j This warranty shall cease to have effect if the Purchaser removes or defaces or alters the Manufacturer’s Number or Name Plates or any other numbers or marks affixed to any JCB Product. k In respect of machines sold which have been used since the date of manufacture by the Manufacturer for demonstration purposes the term of this warranty shall be three months.

EQUIPMENT REGISTRATION CARD/CARTE DÕENREGISTREMENT-DÕEQUIPEMENT/ GER€TE-GARANTIEKARTE/GARANTIEKAART/SCHEDA DI REGISTRAZIONE PER ATTREZZATURE For the Warranty to become effective the self-addressed card below must be completed and returned within 14 days of retail purchase.

Pour que la garantie soit valide, il est impératif que la fiche ci-dessous nous soit renvoyée à l'adresse indiquée sur celle-ci, et ce dans un délai de 14 jours à compter de la date de l'achat au détail.

Um die Garantie wirksam zu machen, muß die untenstehende adressierte Karte innerhalb von 14 Tagen nach dem Kauf ausgefüllt und eingesandt werden.

Para la Garantía sea efectiva, por favor rellene la tarjeta adjunta y remitanosla dentro de los 14 días siguientes a la fecha de compra.

Om de garantie van kracht te laten worden moet de antwoordkaart hieronder binnen 14 dagen na aankoop van het product ingevuld worden geretourneerd.

Per attivare la garanzia compilare la scheda con indirizzo prestampato e restituirla entro 14 giorni dall'acquisto.

Warranty Department, JCB ATTACHMENTS Riverside, Rugeley, Staffordshire, England, WS15 2WA FOR YOUR RECORD/POUR VOS ARCHIVES/FÜR IHRE AKTEN/PARA SU REGISTRO/VOOR UW ARCHIEF/ PER I VOSTRIARCHIVI EQUIPMENT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TYPE D’EQUIPEMENT/GERÄT/TIPO DE EQUIPO/ UITRUSTING TYPE/TIPO DI ATTREZZATURA SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No DE SERIE/SERIENNUMMER/No DE SERIE/ SERIENR./NUMERO DI SERIE DATE RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DATE REÇU/LIEFERDATUM/FECHA DE RECEPCION/ DATUM VAN ONTVANGST/DATA DI RICEZIONE PURCHASED FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACHETE CHEZ/GEKAUFT VON/COMPRADO DE/ GEKOCHT BIJ/ACQUISTATA PRESSO

JCB ATTACHMENTS EQUIPMENT REGISTRATION CARD/CARTE D’ENREGISTREMENT - D’EQUIPEMENT/ TARJETA DE REGISTRO DE EQUIPOS/GERÄTE-GARANTIEKARTE/ GARANTIEKAART/SCHEDA DI REGISTRAZIONE PER ATTREZZATURE EQUIPMENT TYPE TYPE D’EQUIPEMENT/GERÄT/TIPO DE EQUIPO UITRUSTING TYPE/TIPO DI ATTREZZATURA Serial No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No de Série:/Seriennummer/No de Serie: Serienr.:/N. di Serie: Purchased from: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acheté chez:/Gekauft von/Comprado de: Gekocht bij:/Acquistata presso: Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adresse:/Anschrift/Dirección: Adres:/Indirizzo: Date received: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date reçu:/Lieferdatum/Fecha de recepción: Datum van ontvangst:/Data di ricezione: Your Company Name: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nom de votre Firme:/Ihre Firmenbezeichnung/Nombre de la Empresa:/Uw firmanaam:/Nominativo della vostra ditta Address:/Adresse:/Anschrift:/Dirección/Adres:/Indirizzo: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................................................................... ...............................................................................................

Tel. No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No. de téléphone:/Telefonnummer:/No. Teléfono/Tel. Nr./Tel. N. E/F/G/S/Du/L

9804/7133 Iss. 5

JCB ATTACHMENTS

Warranty Department JCB Attachments Riverside, Rugeley, Staffordshire England, WS15 2WA