JCB Large Hydraulic Breakers Owners Manual 9814-0526

Description

• Model List:
  • Large Hydraulic Breakers

• 1. Warranty pages to be found at the front of this manual
• 2. 1 About this Manual……………………………………………………………………………………………………………….1
• 3. 2 Safety Notices ……………………………………………………………………………………………………………………2
• 4. 2.1 General Safety…………………………………………………………………………………………………………4
• 5. 2.2 Safety Decals ………………………………………………………………………………………………………….6
• 6. 3 Technical Specifications ……………………………………………………………………………………………………..9
• 7. 3.1 Breaker Specification ……………………………………………………………………………………………….9
• 8. 3.2 Working Pressure-Required Flow-Engine RPM…………………………………………………………..14
• 9. 4 Main Components ……………………………………………………………………………………………………………19
• 10. 5 Installation ……………………………………………………………………………………………………………………….20
• 11. 5.1 Consumables ……………………………………………………………………………………………………….20
• 12. 5.1.1 Mineral hydraulic oil ………………………………………………………………………………………………20
• 13. 5.1.2 Non-mineral hydraulic oil ……………………………………………………………………………………….20
• 14. 5.1.3 Grease …………………………………………………………………………………………………………………20
• 15. 4.1.4 Gas ……………………………………………………………………………………………………………………..21
• 16. 5.2.1 Attaching the hanger bracket to the hydraulic breaker ………………………………………………21
• 17. 5.2.2 Installing-Removing the Breaker – Preparation …………………………………………………………..22
• 18. 5.3 Mounting the hydraulic breaker on the excavator mechanical aspects ………………………..23
• 19. 5.4 Mounting the hydraulic breaker on the excavator ……………………………………………………..24
• 20. 5.5 Dismounting the hydraulic breaker from the excavator for short or lengthy periods
• 21. of non-use ……………………………………………………………………………………………………………25
• 22. 5.5.1 Dismounting from excavator …………………………………………………………………………………..25
• 23. 5.5.2 Short period of non-use …………………………………………………………………………………………26
• 24. 5.5.3 Lengthy period of non-use ……………………………………………………………………………………..26
• 25. 6 Fitting-Removing the Tool …………………………………………………………………………………………………27
• 26. 6.1 Selecting the right tool …………………………………………………………………………………………..27
• 27. 6.1.1 Tools for hydraulic breakers JCB HM Large Breakers ………………………………………………..27
• 28. 6.2 Fitting the tool (After breaker delivery to the site) ………………………………………………………28
• 29. 6.3 Removing the tool …………………………………………………………………………………………………28
• 30. 7 Installation – Control Settings ……………………………………………………………………………………………29
• 31. 7.1 Carrier machine procedures…………………………………………………………………………………….29
• 32. 7.2 Breaker flow, pressure and ARV settings…………………………………………………………………..29
• 33. 8 Operating the Hydraulic Breaker ………………………………………………………………………………………32
• 34. 8.1 Starting up the hydraulic breaker …………………………………………………………………………….32
• 35. 8.2 Operation ……………………………………………………………………………………………………………..32
• 36. 8.3 Angle of attack ……………………………………………………………………………………………………..33
• 37. 8.4 Breaker rocking …………………………………………………………………………………………………….33
• 38. 8.5 Never drive the working tool into the ground ……………………………………………………………33
• 39. 8.6 Never lever with the breaker …………………………………………………………………………………..33
• 40. 8.7 Never use as a sledgehammer ……………………………………………………………………………….34
• 41. 8.8 Never use for transport purposes ……………………………………………………………………………34
• 42. 8.9 Using the hydraulic breaker in or under water …………………………………………………………..34
• 43. 8.10 Hydraulic breaker used in tunnelling ………………………………………………………………………..35
• 44. 8.11 Working in high outside temperatures ……………………………………………………………………..35
• 45. 8.12 Working in low outside temperatures ………………………………………………………………………35
• 46. 8.13 Operating the breaker with the cylinders fully extended or retracted …………………………..35
• 47. 9 Maintenance Work to be Performed by the Excavator Driver …………………………………………….36
• 48. 9.1 Automatic lubrication on breakers …………………………………………………………………………..36
• 49. 9.1.1 Automatic lubrication using JCB AUTOGREASE ………………………………………………………36
• 50. 9.1.2 Changing the lubricant cartridge …………………………………………………………………………….36
• 51. 9.1.3 Operating the JCB AUTOGREASE ………………………………………………………………………….37
• 52. 9.2 Manual lubrication without or upon failure of JCB AUTOGREASE ………………………………38
• 53. 9.2.1 Filling method for the JCB Extreme Hammer Grease Cartridge …………………………………..38
• 54. 9.3 Care and maintenance timetable …………………………………………………………………………….39
• 55. 9814-0526-01 79.4 Checks required ……………………………………………………………………………………………………40
• 56. 9.4.1 Checking the working tool for wear …………………………………………………………………………40
• 57. 9.4.2 Checking the wear bushes and buffer ring ……………………………………………………………….40
• 58. 9.4.3 Checking the retainer bars for wear …………………………………………………………………………41
• 59. 9.4.4 Checking the impact face of the percussion piston …………………………………………………..41
• 60. 9.4.5 Checking the breaker housing for wear and cracks and checking the breaker bracket for
• 61. cracks ………………………………………………………………………………………………………………….41
• 62. 9.4.6.1 Screw couplings with tightening torques ………………………………………………………………….42
• 63. 9.4.6.2 Identification of screw couplings ……………………………………………………………………………..43
• 64. 9.4.7 Checking pressure in piston accumulator and refilling if required ……………………………….44
• 65. 9.4.8 Checking that the high pressure accumulator is in perfect working order ……………………46
• 66. 9.4.9 Checking the hydraulic lines before starting work ……………………………………………………..46
• 67. 9.4.10 Checking the hanger brackets bolts for wear ……………………………………………………………46
• 68. 9.4.11 Checking and cleaning the hydraulic oil filter ……………………………………………………………46
• 69. 10 Troubleshooting ……………………………………………………………………………………………………………….47
• 70. 10.1 Breaker does not start …………………………………………………………………………………………..47
• 71. 10.2 Impact rate of hydraulic breaker too low ………………………………………………………………….48
• 72. 10.3 Impact force too low ……………………………………………………………………………………………..48
• 73. 10.4 Impact rate too high and impact force too low …………………………………………………………49
• 74. 10.5 Oil leaks from ports »P« and »T« …………………………………………………………………………….49
• 75. 10.6 Oil leaks between cylinder cover and cylinder ………………………………………………………….49
• 76. 10.7 Oil leaks from parts of hydraulic system for breaker (Screw couplings, hoses etc.) ………49
• 77. 10.8 Oil leaks from tool …………………………………………………………………………………………………49
• 78. 10.9 Oil leaks from high-pressure accumulator ………………………………………………………………..49
• 79. 10.10 Oil or grease leaks from JCB AUTOGREASE ……………………………………………………………50
• 80. 10.11 Operating temperature too high ………………………………………………………………………………50
• 81. 11 Disposal of Consumables …………………………………………………………………………………………………50
• 82. 12 Hydraulic Oils, Filtering and Cooling …………………………………………………………………………………51
• 83. 13 Nitrogen Adaptor Reference Chart…………………………………………………………………………………….53
• 84. 14 Tool Part Numbers…………………………………………………………………………………………………………….54
• 85. 15 Breaker Part Number Matrix ……………………………………………………………………………………………..55