jcb 929/92400 Service Manual
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jcb 929/92400 Service Manual

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JCB Attachments, Riverside, Rugeley, Staffordshire WS15 2WA, England
Tel: 01889 572700
*9803/1250*
9803/1250
ISSUE 2
MAY 04
PRINTED IN ENGLAND
SERVICE MANUAL
JCB HAND HELD
HYDRAULIC
EQUIPMENT

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Summary of Contents for jcb 929/92400

  • Page 1 SERVICE MANUAL JCB Attachments, Riverside, Rugeley, Staffordshire WS15 2WA, England JCB HAND HELD Tel: 01889 572700 HYDRAULIC EQUIPMENT *9803/1250* 9803/1250 ISSUE 2 MAY 04 PRINTED IN ENGLAND...
  • Page 2 Study this service manual before attempting to maintain the breaker. You must understand and follow the instructions in this service manual. If you are unsure of anything ask your JCB dealer or employer. Do not guess, or you or others could be killed or seriously injured.
  • Page 3 INTRODUCTION ABOUT THIS MANUAL To ensure that the JCB series of hydraulic breakers BREAKER MODEL AND SERIAL NUMBER can be operated efficiently and safely, they must be serviced and maintained regularly. This manual is The following breakers are covered by this manual: designed to give you a good understanding of the breaker and provide detailed maintenance information.
  • Page 4 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.
  • Page 5 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.

  • Page 6: Table Of Contents

    MAINTENANCE CONTENTS Lubricants - Health and Safety Hygiene Storage Handling First aid - Oil Fires Waste disposal Service Schedules Daily Monthly Breaker dismantling - HM22, 25, 29 Breaker inspection - HM22, 25, 29 Breaker assembly - HM22, 25, 29 Charging the accumulator Equipment required Charging pressure Charging procedure...

  • Page 7: Lubricants - Health And Safety

    Wash dirty clothing before reuse. Hygiene h Throw away oil soaked shoes. JCB lubricants are not a health risk when used First Aid-Oil properly for their intended purpose. Swallowing However, excessive or prolonged skin contact can If oil is swallowed do not induce vomiting.

  • Page 8: Service Schedules

    JCB Attachments. listed in the service schedules are done to keep the equipment in a safe and efficient working condition. Any defects found during the regular routine maintenance checks must be rectified before the equipment is used.
  • Page 9 MAINTENANCE BREAKER DISMANTLING - HM 22, 25, 29 Prepare for oil spillage and remove the two upper Using a press, remove roll pins Q from the barrel fixing capscrews. Remove the barrel A. nose.This releases latch R, latch plunger S and the plunger spring.

  • Page 10: Breaker Dismantling - Hm22, 25, 29 B3

    MAINTENANCE BREAKER DISMANTLING - HM 22, 25, 29 (cont’d) Remove the seals from the lower section of the 10 Remove screws (4 off each cover) from covers N barrel casting. A slide hammer will be necessary (2 off), this will expose the handle mechanism. to remove the seal housing.
  • Page 11 MAINTENANCE BREAKER DISMANTLING - HM 22, 25, 29 (cont’d) 13 Remove the cover screw T to expose the 16 Remove the four top cover retaining screws P charging screw. and remove the cover. Note: There are two long and two shorter retaining screws 17 Remove the trigger pin W and the ‘O’...
  • Page 12 MAINTENANCE BREAKER INSPECTION - HM 22, 25, 29 Examine the piston C, piston feeder D and barrel Examine the seals for signs of wear. Pay A for signs of damage. Small scratches can be particular attention to their lips. Obtain new seals carefully removed with fine emery cloth.

  • Page 13: Breaker Inspection - Hm22, 25, 29 B6

    MAINTENANCE BREAKER INSPECTION - HM 22, 25, 29 (cont’d) Examine the roll pins Q, latch R, latch plunger S 10 Check the spring ring aa, guide rings ff (2 off), and plunger spring for signs of damage or wear. carrier ii, spring jj and tool bush nn for damage Obtain new components if necessary.
  • Page 14 Note: During assembly, apply Multi Gasket Loctite Fit the trigger pin O into the handle bracket. Fit 518 (JCB Part No. 4102/1212) to all joint faces. Use the handle bracket to the head. Treat the threads new seals and ‘O’ rings throughout.

  • Page 15: Breaker Assembly - Hm22, 25, 29 B8

    MAINTENANCE BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d) Treat the thread of the pivot pin Z with Loctite Assemble the seals into the lower section of the 270 and fit the pin where indicated. barrel casting A. Ensure seal ss has the open face uppermost,seal zz is fitted in the same direction.
  • Page 16 MAINTENANCE BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d) 12 Bolt the barrel A to the nose B. Torque tighten 15 Replace covers N (2 off). the capscrews progressively using a Gedore narrow head torque wrench (part no. 7200-01). See Torque Figures on Page A2 13 Fit 3 new seals into barrel A.

  • Page 17: Charging The Accumulator B11

    Connecting hose Suitable hose of minimum operating pressure 207 bar (3000 lbf/in , together with female coupling (JCB part Disconnect the charging hose 4 and unscrew the no.929/06303). charging adaptor 3 from the body of the breaker. CHARGING PRESSURE Finally, tighten the charging screw using a 4mm.
  • Page 18 MAINTENANCE OPERATOR FAULT FINDING *The remedy in certain cases should be carried out by your JCB dealer Symptom Possible Fault Remedy Breaker fails to operate. No flow from supply. *Check output with flow and pressure tester. Hoses incorrectly fitted. Check that pressure feed is connected to top port on the breaker.
  • Page 19 MAINTENANCE BREAKER HM26 (NON EU) Issue 1 9803/1250...
  • Page 20 MAINTENANCE 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.
  • Page 21 MAINTENANCE BREAKER - HM22, 25, 29 Issue 1 9803/1250...
  • Page 22 MAINTENANCE CONTENTS Breaker dismantling - Standard and Vibro-damped Breaker inspection - Standard and Vibro-damped Breaker assembly - Standard and Vibro-damped Breaker dismantling - ‘D’ and ‘T’ picks Breaker inspection - ‘D’ and ‘T’ picks Breaker - ‘D’ and ‘T’ picks Charging the accumulator Equipment required Charging pressure...

  • Page 23: Breaker Dismantling - Standard And Vibro-Damped

    MAINTENANCE BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED ! WARNING ! WARNING Accumulator The breaker must be disconnected from its source The breaker incorporates a pressure accumulator. of hydraulic power before any maintenance is This accumulator is pressurised even when there is carried out.
  • Page 24 MAINTENANCE BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d) Unscrew and remove check valve E ensuring that Remove the seals from the lower section of the the breaker is positioned as shown above so as to barrel casting. A slide hammer will be necessary avoid losing the check valve ball F.
  • Page 25 MAINTENANCE BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d) 12 For vibro-damped handle breakers only, remove 13 For vibro-damped handle breakers only, the four top cover retaining screws P and remove unscrew the handle pivot pin Z nearest the trigger the cover. pin.
  • Page 26 MAINTENANCE BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d) 17 Loosen charging screw slowly 18 For standard handle breakers only, when you approximately 3 or 4 turns, listening for all the gas are sure that all the gas in the accumulator has to escape.

  • Page 27: Breaker Inspection - Standard And Vibro-Damped

    MAINTENANCE BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED Examine the piston C, piston feeder D and barrel Examine the check valve ball F and ball seats for A for signs of damage. Small scratches can be signs of damage or excessive wear. Obtain new carefully removed with fine emery cloth.
  • Page 28 MAINTENANCE BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED (cont’d) Examine the roll pins Q, latch R, latch plunger S Examine the diaphragm X for signs of damage. and plunger spring for signs of damage or wear. Pay particular attention for signs of cracking Obtain new components if necessary.

  • Page 29: Breaker Assembly - Standard And Vibro-Damped

    A-3-1-4 Note: During assembly, apply Multi Gasket Loctite 574 (JCB Part No. 4102/1201) to all joint faces. Place diaphragm X into the head, ensuring that the diaphragm insert is uppermost (as shown above). Fit new ‘O’ ring seal Y.
  • Page 30 MAINTENANCE BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d) Treat thread of safety screw V with Loctite 242 For vibro-damped handle breakers only, fit the and fit the safety screw into the head. 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).
  • Page 31 MAINTENANCE BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d) 12 Assemble the seals into the lower section of the 13 Treat the thread of check valve E with Loctite 542. barrel casting. Ensure that the open faces of the Fit the check valve and its ball F into the barrel by seals are fitted as shown on inset.

  • Page 32: Breaker Dismantling - 'D' And 'T' Picks

    MAINTENANCE BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS ! WARNING ! WARNING The pick must be disconnected from its source of Accumulator hydraulic power and the oil drainer before any The breaker incorporates a pressure accumulator. maintenance is carried out. This accumulator is pressurised even when there is no hydraulic pressure to the breaker.
  • Page 33 MAINTENANCE BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d) ‘D’ Type only. Remove the retainer 13 with the ‘T’ Type only. If necessary, remove roll pins 18 bump stop 14. Remove and discard ‘O’ ring 15. and 19 suing a press. Remove the latch 20, ‘T’...
  • Page 34 MAINTENANCE 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.
  • Page 35 MAINTENANCE BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d) 17 Remove the two grub screws 48 from the lower 18 Clamp the barrel/nose assembly in a vice and end of the barrel 49 (one each side). unscrew the now 50 from the barrel 49, using a ‘C’...

  • Page 36: Breaker Inspection - 'D' And 'T' Picks

    MAINTENANCE BREAKER INSPECTION - ‘D’ and ‘T’ PICKS ‘T’ Type only. Examine the roll pins 18 and 19, Examine the housing cap 29 and spool 32 for latch 20, plunger 21 and plunger spring 22 for signs of damage. Obtain new components if signs of damage or wear.
  • Page 37 MAINTENANCE BREAKER INSPECTION - ‘D’ and ‘T’ PICKS (cont’d) Examine slide rails 24 and springs 25 for signs of Examine slide bearings 26 and bump stops 27 for excessive wear, damage or deformation. Replace signs of damage or excessive wear. Replace if if necessary.

  • Page 38: Breaker - 'D' And 'T' Picks

    ‘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. Insert new seal 51 into the lower end of barrel 49.
  • Page 39 MAINTENANCE BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d) Fit the diaphragm 42 into the accumulator head Turn the accumulator assembly over. Insert 41, ensuring the diaphragm insert is uppermost. trigger spool 36 into accumulator assembly. Fit Assembly the accumulator top 40 onto the head spring 35, seal 34 and plug 33.
  • Page 40 MAINTENANCE BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d) 12 ‘T’ Type only. If dismantled, fit the spring 22, 13 Fit new ‘O’ ring seal 15 onto the nose 52, taking plunger 21 and latch 20 into the nose latch. Using care not to damage it on the exposed thread.

  • Page 41: Charging The Accumulator

    Do not (800 lbf/in overtighten. Charging adaptor (JCB part No. 929/05800) Shut the regulator valve on the nitrogen bottle and together with 3/8 in. BSP Dowty washer. using the venting screw 7A, release the trapped gas in the hose.

  • Page 42: Fault Finding

    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.
  • Page 44 SPECIFICATION CONTENTS JCB hydraulic breakers Standard Breakers Vibro-damped breakers D1/D2 ‘D’ and ‘T’ breakers Noise and vibration data Issue 1 9803/1250...

  • Page 45: Jcb Hydraulic Breakers

    25 mm 1 in. Model No. 929/07200 & 08200 32 mm 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 22 kg 44 lb Model Nos.

  • Page 46: D' And 'T' Breakers

    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 12 kg 26.4 lb...

  • Page 47: Noise And Vibration Data

    SPECIFICATION NOISE AND VIBRATION DATA Model No. Handle Type Noise Level EC Vibration Weighted Directive 84/457/ RMS Acceleration ISO EEC (LWA) 8662 Part 5 (m/s 929/05300 Vibro-Damped 929/05400 Standard 18.9 929/05500 Vibro-Damped 929/05600 Standard 18.9 929/07400 Vibro-Damped 929/07200 Standard 16.6 929/08300 Vibro-Damped 929/08200...
  • Page 48 The range of hydraulic powerpacks are categorised by GENERAL DESCRIPTION EHTMA as Category ‘C’ or ‘D’ hydraulic powerpacks The JCB Hydraulic powerpacks have been specially and can be safely used with any hydraulic tool developed to provide a lightweight source of portable displaying the EHTMA ‘C’...
  • Page 49 MAINTENANCE HYDRAULIC POWERPACKS MAINTENANCE Service Schedules Apart from the daily jobs, the schedules are based on Safety Decals machine running hours. Keep a regular check of hours Keep all decals clean and readable. Replace lost or in use. Do not use a machine which is due for a regular damaged decals.
  • Page 50 MAINTENANCE HYDRAULIC POWERPACKS Changing the Hydraulic Oil Checking the Electrolyte Level ! WARNING Prepare the Machine - Position the machine on level ground. Switch off the engine and allow it to Battery electrolyte contains sulphuric acid. It can cool down. burn you if it touches your skin or eyes.
  • Page 51 SPECIFICATIONS HYDRAULIC POWERPACKS Engines The BEAVER III may be fitted with a Honda GX240 petrol engine. These engines are fitted with an Oil Alert system which is designed to prevent engine damage caused by an insufficient amount of oil in the crank case.

This manual is also suitable for:

929/05400929/05500929/05600929/07400929/07200929/08300 ... Show all

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