Service Manual: HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 Onwards

HM Medium Breakers 1
HM Large Breakers 2
Service
Manual
HM Range Medium
and
Large Hydraulic
Breakers,
Serial Nos.
1095001 onwards
Published by
JCB Attachments
Waterloo Park, Beamhurst
Uttoxeter, Staffordshire ST14 5PA
England
Tel: +44 (0)1889 506043
PRINTED IN ENGLAND
Publication No. 9803/1420_04
Service Manual
Section 1 - Medium Breakers
Publication No.
9803/1420-04
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
0 9803/1420-04 0
Contents Page No.
Medium Breakers
Introduction .................................................................................................... 1
Safety ....................................................................................................... 1
General Information .................................................................................. 1
Workshop Standards ................................................................................ 1
Spare Parts ............................................................................................... 1
Service Personnel .................................................................................... 1
Using this Manual ..................................................................................... 2
Standard Symbols ......................................................................................... 3
Service Tools ................................................................................................. 5
Charging Equipment .................................................................................... 10
Medium Breakers - HM165Q, 265Q, 385Q, 495Q

Dismantling .................................................................................................. 11
Assembly ..................................................................................................... 18
Field Bushing Exchange .............................................................................. 23
Charging the Accumulator ........................................................................... 25
Hanger Brackets .......................................................................................... 27
Exploded Views ........................................................................................... 28
Operating Principles .................................................................................... 32
Stage 1 - Start Up ................................................................................... 32
Stage 2 - Return Stroke .......................................................................... 32
Stage 3 - Power Stroke ........................................................................... 33
Stage 4 - End of Power Stroke ............................................................... 33
Medium Breakers - HM386Q

Special Tools ............................................................................................... 34
Dismantling .................................................................................................. 38
Assembly ..................................................................................................... 45
Operating Principles .................................................................................... 54
Stage 1 ................................................................................................... 54
Stage 2 ................................................................................................... 54
Stage 3 ................................................................................................... 55
Stage 4 ................................................................................................... 55
Stage 5 ................................................................................................... 56
Medium Breakers
Technical Specifications .............................................................................. 57
Nitrogen Adaptor Reference Chart .............................................................. 58
Tool Part Numbers ....................................................................................... 63
Breaker Part Number Matrix ........................................................................ 64
i i
Page left intentionally blank
ii ii
Medium Breakers
Introduction
Safety Any unauthorised use or copying of the contents of this

manual or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part
This safety alert system identifies numbers and drawings.
important safety messages in this
manual. When you see this symbol, be
Workshop Standards
alert, your safety is involved, carefully
read the message that follows, and inform
JCB HM Breakers have hydraulically powered percussion
other operators.
mechanisms. Since all hydraulically powered equipment is
sensitive to dirt, the breakers must always be
The words WARNING and CAUTION have the following disassembled in a place that is:
meanings:
– Isolated from all dust and particle-generating
!MWARNING activities such as grinding and welding.
– Very clean, i.e. free of dust and dirt.
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or – Equipped with washing facilities and compressed air
seriously injured. for the blow cleaning of components.
INT-1-2-2 – Equipped with all the necessary standard and special
tools.
!MCAUTION
Denotes a reminder of safety practices. Failure to !MWARNING
follow these safety practices could result in injury to The tool must not be modified without the
the operator (or others) and possible damage to the manufacturer’s permission. Use only original parts
machine. and accessories approved by JCB Service. If
INT-1-2-3 modifications are made that are not approved by JCB
Service, serious harm to yourselves or others may
General Information result.
TTG
The following instructions are intended to guide service
personnel in the repair or overhauling of the JCB Medium Spare Parts
Breakers.
Use only authorised parts. Any damage or malfunction
!MWARNING caused by the use of unauthorised parts will not be
covered by any warranty or product liability.
NEVER intervene in the breaker when it is connected
to the hydraulic system, or when the accumulator is
charged. Service Personnel
TTG
This manual is designed for the benefit of JCB Distributer
All users of this manual are asked to inform JCB Service Engineers who are receiving, or have received,
Attachments if they find any errors or discrepancies, training by the JCB Training Centre or by JCB Service
especially any affecting product safety. Personnel. These personnel should have a sound
knowledge of workshop practice, safety procedures and
general techniques associated with the maintenance and
repair of hydraulic equipment.
1 9803/1420-04 1
Medium Breakers
Introduction
Renewal of seals, gaskets etc. and any components
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.
Finally, please remember above all else - SAFETY MUST
COME FIRST!
Using this Manual

This manual begins with a list of the symbols and tools
used in the overhaul procedures. This is followed by
instructions on how to dismantle the breaker into its
component parts, the checking and inspection of parts,
and then reassembly.
2 9803/1420-04 2
Medium Breakers
Standard Symbols
Standard Symbols
Important positional Direction Inspect and replace New parts

relationship damaged parts
To be avoided Okay Force Turning to end position
Oil Loctite 243 Gas release Scrap
Contact sound Minutes Grease Frozen
3 9803/1420-04 3
Medium Breakers
Standard Symbols
Torque On the excavator Cracks In turn
4 9803/1420-04 4
Medium Breakers
Service Tools
Service Tools
Use this as a checklist before working on the breakers.
Item Description
Plastic hammer
Allen socket: 5, 8, 14 mm
Screwdriver
Punch 10 mm
Torque wrench 0 - 650 Nm
Allen sockets for torque wrench: 5, 6, 8, 10, 14 mm
Vernier gauge
Ratchet wrench
5 9803/1420-04 5
Medium Breakers
Service Tools
Item Description
Scriber
Open-ended spanners: 13, 14, 15, 17, 19, 24, 27, 30, 36 mm
Sockets for torque wrench: 17, 24, 30, 36 mm
Circlip pliers
Slide hammer
6 9803/1420-04 6
7
Item Part No. Description HM165Q HM265Q HM365Q HM495Q

998/11247 Shackle Disassembly/assembly of piston and z z
liner
Comprises of:
998/11228 Extractor assembly z z
1370/0901 M24 Nut z z
998/11229 Screw z z
998/11230 Foot z z
998/11231 Disk z z
998/11232 Tube z z
998/11245 Extractor Removal of piston guide z z
Comprises of:
998/11217 Handle z z
9803/1420-04
998/11218 Weight z z
998/11219 Pull rod z z
998/11220 Disk z
826/00920 Roll pin z z
2203/0012 M10 Circlip z z
1370/0301 M10 Nut z z
998/11221 Disk z
TBA Mandrel Fitting of liner assembly
Medium Breakers
Service Tools
7
8

TBA Extractor Removal of bushing
998/11253 Mandrel Assembly of bushing z

998/11254 z
9803/1420-04
TBA Assembly tool Helicoil thread inserts
998/11249 Removal tool Removal of tool bushing z

Comprises of:
998/11235 Screw z
Medium Breakers
998/11236 Threaded Tube z
998/11237 Tube z
Service Tools
8
9

998/11246 Removal tool Removal of bushing z
Comprises of:
998/11222 Core z
998/11223 Handle z
998/11224 Sleeve z
998/11225 Sleeve z
998/11226 Striker z
998/11227 M25 Pin z
1391/3405 Bolt M10 x 20 z
998/11240 Mandrel z
998/11241 z
9803/1420-04
998/11242 Drift Rear wiper seal z
Medium Breakers
Service Tools
9
Medium Breakers
Charging Equipment
Charging Equipment
Item Part No. Description

TBA Charging hose Hose for charging accumulators
complete with
adaptor
998/11322 Gas regulator Charging of high pressure and low

998/11365 complete with pressure accumulators
pressure gauge
10 9803/1420-04 10
Dismantling
1420_107
11 9803/1420-04 11
Dismantling
1420_108
12 9803/1420-04 12
Dismantling
1420_109
13 9803/1420-04 13
Dismantling
mm mm mm mm
HM165Q 37.900 46.995 44.940 1.5
HM265Q 44.900 64.920 53.930 1.5
HM385Q 62.400 74.950 72.950 1.5
HM495Q 69.300 84.340 81.940 1.5
1420_110
14 9803/1420-04 14
Dismantling
1420_111
15 9803/1420-04 15
Dismantling
HM165Q
HM265Q
100 Nm
HM385Q
150 Nm
HM495Q
300 Nm
1420_112
16 9803/1420-04 16
Dismantling
HM385Q < 83 mm
HM165Q < 53 mm
HM385Q > 83 mm
HM165Q > 53 mm
HM495Q < 98 mm
HM265Q < 68 mm
HM495Q > 98 mm
HM265Q > 68 mm
HM385Q - O 72 mm
HM495Q - O 85 mm
HM165Q - O 55 mm
HM265Q - O 70 mm
1420_113
17 9803/1420-04 17
Assembly
Assembly
1420_114
18 9803/1420-04 18
Assembly
1420_115
19 9803/1420-04 19
Assembly
3” #
1420_116
20 9803/1420-04 20
Assembly
HM385Q
300 Nm
HM495Q
650 Nm
HM165Q
HM265Q
200 Nm
1420_117
21 9803/1420-04 21
Assembly
HM385Q
HM495Q
190 Nm
HM265Q
120 Nm
HM165Q
75 Nm
1420_118
22 9803/1420-04 22
Field Bushing Exchange
1420_119
23 9803/1420-04 23
1420_120
24 9803/1420-04 24
Charging the Accumulator
1420_123
25 9803/1420-04 25
1420_124
26 9803/1420-04 26
Hanger Brackets
Hanger Brackets
If the breaker hanger bracket is changed, ensure it has the

correct orientation. Later hanger brackets have a cross
welded to the side plate denoting the dipper pivot.
Table 1. Tightening Torque

Model Bolt Size
HM165Q, 265Q, 385Q, 495Q M16 200 Nm(1)
(1) For bolts used with nord-lock washers and thread

inserts. If a non JCB hanger bracket is used, refer to
the relevant manufacturers documentation.
27 9803/1420-04 27
Exploded Views
Exploded Views
Tightening torque 22 21 19 23
Pos 5 = 95 Nm 18
Pos 6 = 40 Nm 14
Pos 13 = 30 Nm 13 24
Pos 17 = 75 Nm
Pos 18 = 75 Nm 12
11 22 21 20 23
Pos 37 = 200 Nm
Pos 56 = 200 Nm 15
16
25
10
9 26
8
7
28 27
3 17
5 6
2 29
1 31 32 7
34
30 33 56
43
4
37 35
36 36
40
Atlas Copco Berema AB
42 Type TEX 110 H
NACKA SWEDEN
i
39 Ser No 1234567890
Pmax bar(e)
!
xxxx xxxx xx Made in Sweden
41 38
53
44 45 46 47 48 46 49 51 51 46 52 54 46 55 56
1420_127
Fig 1. HM165Q
28 9803/1420-04 28
Exploded Views
Tightening torque
Pos 5 = 95 Nm Loctite 243
Pos 12 = 40 Nm Loctite 243 14
Pos 13 = 120 Nm
Pos 17 = 30 Nm 16
Pos 22 = 120 Nm
Pos 30 = 100 Nm
Pos 31 = 200 Nm
Pos 35 = 30 Nm 13
18
Pos 55 = 200 Nm 17
15
98 7 10
19
20
6
21 32
12 Atlas Copco Berema AB
NACKA SWEDEN
Type TEX XXX
Ser No 1234567890 ! i
23 22
Pmax 7 bar(e)
xxxx xxxx xx Made in Sweden 199x
11 56
3 5 24
2 25
27 28
1 29
61 26 30 31
60 4
55 54 54 53
58 38 34
59 35
38 36 33
37
5
57
49
39 40 41 42 43 46 29 47 48 50 52
44 45 44 45 45 44 51
1420_128
Fig 2. HM265Q
29 9803/1420-04 29
Exploded Views
1420_125
Fig 3. HM385Q
30 9803/1420-04 30
Exploded Views
Tightning torque
1420_126
Fig 4. HM495Q
31 9803/1420-04 31
Operating Principles
Stage 1 - Start Up Stage 2 - Return Stroke
1420_130a
Fig 6.
1420_129a
Fig 5. When the rear edge of the piston meets the main valve C,
the holding force is overcome and the valve moves
When the hammer is started, the front cylinder chamber is backwards.
pressurised. At the same time, the accumulator and the
pins B, which give a holding force on the main valve C, are When the front edge of the valve uncovers port D, the front
pressurised via the channel A. edge becomes pressurised, causing the valve to move
backwards more rapidly than the piston. The rear cylinder
This causes the piston to begin its return stroke. chamber is now pressurised. This causes the piston to
begin its working stroke because of the difference in the
front and rear piston pressure areas.
32 9803/1420-04 32
Stage 3 - Power Stroke Stage 4 - End of Power Stroke
1420_131a
Fig 7.
1420_132a
Fig 8.
The job of the accumulator is to keep the pressure at
maximum level during the working stroke of the piston. At the same time as the valve closes port D, port F is
uncovered. Now only the front cylinder chamber is
When the rear edge of the piston uncovers port E, the back pressurised, which causes the piston to make another
of the valve becomes pressurised. This causes the valve return stroke.
to move forward and close port D.
When this happens, the hydraulic oil in the rear cylinder
chamber flows back to the tank via the return line.
33 9803/1420-04 33
Special Tools
The following tools are special tools required for

dismantling and assembly of the breaker. These tools can
be manufactured locally from the drawings shown.
ST1
1420_7a
34 9803/1420-04 34
Special Tools
ST2 M10 x 130 full threaded
For removal of back head
1420_7b
ST3
1420_8a
35 9803/1420-04 35
Special Tools
ST4
1420_8b
ST5
M6 x 120
E
1420_9a
36 9803/1420-04 36
Special Tools
ST6
1420_9b
ST7 6.3
( )
1.6
NO HARDENED
115
1x45°(2x)
15
M12
5°
Ø25
M12
1.6
15
R8
EDGE BROKEN
60
20
20
1.6
2
R2 (2x)
30° 8°
1.6
Ø40 NITROCARBURIZED
Ø61.5f7 SS2541
1420_10
37 9803/1420-04 37
Dismantling
Dismantling
1. 3.
2. 4.
ST1
1420_15
38 9803/1420-04 38
Dismantling
5. 6.
7.
Warning
The accumulator is pressurized even when the
hydraulic system is shut off. Disassembling
the accumulator before letting the gas out can
cause injury!.
► Let the gas out slowly by opening the
charging valve.
► Make sure that there is no gas pressure in
the accumulator before disassembling the
accumulator housing.
1420_16
39 9803/1420-04 39
Dismantling
8. 11.
12.
9.
13.
10.
1420_17
40 9803/1420-04 40
Dismantling
14. 17.
18.
15.
19.
16.
1420_18
41 9803/1420-04 41
Dismantling
20. 23.
21. 24.
22. 25.
1420_19
42 9803/1420-04 42
Dismantling
26. 27.
28.
1420_20
43 9803/1420-04 43
Dismantling
29. 32.
33.
30.
31. 34.
1420_21
44 9803/1420-04 44
Assembly
Assembly
35. 37.
36.
38.
1420_22
45 9803/1420-04 45
Assembly
39. 41.
42.
40.
43.
1420_23
46 9803/1420-04 46
Assembly
44. 46.
45.
1420_24
47 9803/1420-04 47
Assembly
47. 50.
51.
48.
49.
1420_25
48 9803/1420-04 48
Assembly
52. 53.
54.
1420_26
49 9803/1420-04 49
Assembly
55. 57.
58.
56.
59.
1420_27
50 9803/1420-04 50
Assembly
60. 63.
Warning
The accumulator must only be charged
with Nitrogen (N2). Other gases can cause
explosions.
61.
64.
62.
1420_28
51 9803/1420-04 51
Assembly
65. 66.
67.
1420_29
52 9803/1420-04 52
Assembly
68. 69.
1420_30
53 9803/1420-04 53
Stage 1 Stage 2
1420_S1 1420_S2
Fig 1. Fig 2.
Pressurised oil comes from the excavator pump. The During the return stroke the pressure lifts the diaphragm
pressure is limited to 150 bar by the built in pressure relief support. This compresses the gas in the accumulator to
valve. the same level as the oil pressure.
The pressure lifts the control valve to its upper position and
the upper end of the piston is connected to tank.
At the same time the lower end of the piston gets

pressurised from the pump, causing the piston to start the
return stroke.
54 9803/1420-04 54
Stage 3 Stage 4
1420_S3 1420_S4
Fig 3. Fig 4.
When the piston is in its top position, the lower end of the During the impact stroke, the piston traps the signal
piston allows for a signal pressure to reach the top side of pressure to the control valve, causing it to remain in its
the control valve, causing it to move to its lower position. lower position. The oil and gas pressure in the accumulator
help keeping the hydraulic pressure up during the impact
The inlet oil now passes through the control valve, putting stroke.
pressure on the top end of the piston. The piston starts the
impact stroke.
55 9803/1420-04 55
Stage 5
1420_S5
Fig 5.
When the piston hits the chisel, the control section of the
piston connects the signal channel from the control valve
to tank, allowing the control valve to move back to its upper
position.
The hydraulic oil at the upper end of the piston becomes

connected to tank and loses its pressure. The lower end of
the piston is still under pressure, making the piston start
the return stroke again.
56 9803/1420-04 56
Medium Breakers
57
Technical Specifications
Model HM165Q HM265Q HM385Q HM386Q HM495Q

Service weight (1) 120 kg (265 lb) 200 kg (441 lb) 312 kg (688 lb) 328 kg (722 lb) 419 kg (924 lb)
Serial No. from 1095001 onwards 1095001 onwards 1095001 onwards TBA 1095001 onwards
Recommended carrier class 1.2 - 3.2 tonne (2645 - 2.5 - 8 tonne (5512 - 5 - 8.5 tonne (11023 - 5 - 8.5 tonne (11023 - 6 - 10 tonne (13228 -
70548 lb) 17637 lb) 18740 lb) 18740 lb) 22046 lb)
Impact rate 540 - 1080 blows/min 900 - 1750 blows/min 480 - 960 blows/min 720 - 1380 blows/min 390 - 780 blows/min
Impact energy (calculated) 306 Joules 516 Joules 859 Joules 829 Joules 1058 Joules
Length (excluding tool) 710 mm (28 in) 713 mm (28.1 in) 850 mm (33.5 in) 875 mm (34.4 in) 925 mm (36.5 in)
Oil flow rate 20 - 40 l/min 30 - 65 l/min 50 - 80 l/min 60 - 100 l/min 50 - 90 l/min
(4.4 - 8.8 UK gal/min) (6.6 - 14.3 UK gal/min) (11 - 18 UK gal/min) (13 - 22 UK gal/min) (11 - 22 UK gal/min)
9803/1420-04
(5.3 - 10.6 US gal/min) (8.0 - 17.2 US gal/min) (13 - 21 US gal/min) (16 - 26.5 US gal/min) (13 - 26.5 US gal/min)
Operating pressure 100 - 150 bar (1450 - 100 - 150 bar (1450 - 100 - 150 bar (1450 - 100 - 150 bar (1450 - 100 - 150 bar (1450 -
2176 psi) 2176 psi) 2176 psi) 2176 psi) 2176 psi)
Static pressure (to be set on A.R.V. for Static pressure to be set at 20 bar (290 psi) above measured operating pressure.
breaker circuit)
Maximum return line pressure 20 bar (290 psi) 20 bar (290 psi) 20 bar (290 psi) 35 bar (500 psi) 20 bar (290 psi)
Tool diameter 50 mm (1.97 in) 65 mm (2.6 in) 80 mm (3.15 in) 80 mm (3.15 in) 95 mm (3.75 in)
H.P. accumulator (Minimum gas pressure) (2) 40 bar (580 psi) 40 bar (580 psi) 40 bar (580 psi) 40 bar (580 psi) 40 bar (580 psi)
Sound pressure level measured r - 10 m 95 L dB (A)
P 90 L dB (A)
P 96 L dB (A)
P 93 L dB (A)
P 100 LP dB (A)
(32.8 ft)
Sound power level guaranteed(3) 124 LWA dB (A) 118 LWA dB (A) 125 LWA dB (A) 121 LWA dB (A) 129 LWA dB (A)
Connecting threads on ports ‘P’ and ‘T’ 1/2” BSP 1/2” BSP 3/4” BSP 3/4” BSP 1” BSP
Medium Breakers
Inside diameter
- Hoses 12.5 mm (0.5 in) 19 mm (0.75 in) 19 mm (0.75 in) 19 mm (0.75 in) 25 mm (1 in)
- Pipes 12.5 mm (0.5 in) 19 mm (0.75 in) 19 mm (0.75 in) 19 mm (0.75 in) 25 mm (1 in)
(1) Hydraulic breaker including breaker housing, tool and medium size hanger bracket.
(2) Depending on oil flow rate.
(3) At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure on the tool. Measuring process based on directive 2000/14/EC.
57
Medium Breakers
Nitrogen Adaptor Reference Chart
Country Adaptor Part No. Alternative Part No.

Adaptor
Algeria 40h 892/01202
Argentina 40b 892/01196
Armenia 40n 892/01207 Direct (1) -
Australia 40b 892/01196
Austria Direct (1) -
Azerbaijan 40n 892/01207 Direct (1) -
Bahamas 40b 892/01196
Bahrain 40h 892/01202
Bangladesh 40b 892/01196
Barbados 40b 892/01196
Belgium Direct (1) - 40h 892/01202
Bolivia 40g 892/01201
Botswana 40b 892/01196
Brazil 40g 892/01201
Bulgaria 40n 892/01207 40h 892/01202
Burma 40b 892/01196
Canada 40c 892/01197
Chechenya Direct (1) -
Chile 40g 892/01201
China 40k 892/01204
Columbia 40g 892/01201
Costa Rica 40b 892/01196
Czech Republic Direct (1) -
Denmark Direct (1) -
Djibouti 40h 892/01202
Dom. Republic 40g 892/01201
Ecuador 40g 892/01201
Egypt 40b 892/01196 40h 892/01202
Ethiopia 40b 892/01196
Fiji 40b 892/01196
Finland Direct (1) -
France 40h 892/01202
Gabon 40h 892/01202
Gambia 40b 892/01196
Georgia 40n 892/01207 Direct (1) -
Germany Direct (1) -
Ghana 40b 892/01196
Great Britain 40b 892/01196
Greece 40h 892/01202 40b 892/01196
Guatemala 40g 892/01201
Guinea 40h 892/01202
58 9803/1420-04 58
Medium Breakers

Adaptor
Guyana 40g 892/01201
Honduras 40g 892/01201
Hong Kong 40b 892/01196
Hungary 40h 892/01202
India 40b 892/01196
Indonesia 40b 892/01196
Iran 40h 892/01202
Iraq 40h 892/01202
Ireland 40b 892/01196
Israel 40h 892/01202
Italy 40d 892/01198
Ivory Coast 40h 892/01202
Jamaica 40b 892/01196
Japan 40e 892/01199 40f 892/01200
Jordan 40h 892/01202
Jugoslavia 40h 892/01202
Kazakhstan 40n 892/01207 Direct (1) -
Kenya 40b 892/01196
Korea 40f 892/01200
Kuwait 40h 892/01202
Kyrgyzstan 40n 892/01207 Direct (1) -
Lebanon 40h 892/01202
Libya 40h 892/01202
Liechtenstein Direct (1) -
Luxembourg Direct (1) -
Malawi 40b 892/01196
Malaysia 40l 892/01205 40b 892/01196
Malta 40b 892/01196
Mauritius 40h 892/01202
Mexico 40h 892/01202
Moldova 40n 892/01207 Direct (1) -
Morocco 40h 892/01202
Mozambique 40h 892/01202
Netherlands Direct (1) -
New Zealand 40b 892/01196
Nigeria 40h 892/01202
Norway Direct (1) -
59 9803/1420-04 59
Medium Breakers

Adaptor
Oman 40h 892/01202
Pakistan 40b 892/01196
Paraguay 40g 892/01201
Peru 40g 892/01201
Philippines 40b 892/01196 40o 892/01208
Poland Direct (1) -
Portugal 40b 892/01196
Puerto Rico 40c 892/01197
Qatar 40k 892/01204
Romania 40h 892/01202
Russia Federation 40n 892/01207 Direct (1) -
Saudi Arabia 40h 892/01202 40b 892/01196
Singapore 40b 892/01196
Slovakia Direct (1) -
Slovenia Direct (1) -
South Africa 40b 892/01196
Spain 40h 892/01202
Sri Lanka 40b 892/01196
Sudan 40b 892/01196
Surinam 40b 892/01196
Swaziland 40b 892/01196
Sweden Direct (1) -
Switzerland Direct (1) -
Syria 40h 892/01202
Taiwan 40b 892/01196 40i 892/01203
Tanzania 40b 892/01196
Thailand 40b 892/01196
Trinidad/Tobago 40m 892/01206 40n 892/01207
Tunisia 40h 892/01202
Turkey 40b 892/01196 Direct (1) -
Turkmenistan 40n 892/01207 Direct (1) -
Ukraine Direct (1) -
United Arab Emirates 40h 892/01202
Uruguay 40g 892/01201
USA 40c 892/01197
Uzbekistan 40n 892/01207 Direct (1) -
Venezuela 40n 892/01207
60 9803/1420-04 60
Medium Breakers

Adaptor
Vietnam 40b 892/01196
Zambia 40b 892/01196
(1) Direct means an additional adaptor is not required for connecting the regulator to the gas
bottle.
61 9803/1420-04 61
Medium Breakers
892/01208
892/01205 892/01206 892/01207
892/01202 892/01203 892/01204
892/01199 892/01200 892/01201
892/01196 892/01197 892/01198
62 9803/1420-04 62
Medium Breakers
Tool Part Numbers
Tool Part Numbers
Model Description Diameter Overall Working Tip Width Part No.

Length Length
mm in mm in mm in mm in
HM165Q Moil 50 1.97 510 20.08 310 8.27 - - 331/52394
Narrow chisel 50 1.97 510 20.08 310 12.2 - - 331/52395
Wide chisel 50 1.97 480 19 280 11.02 125 4.92 331/52396
Wide chisel - 50 1.97 480 19 280 11.02 125 4.92 331/52397
transverse
Asphalt cutter 50 1.97 490 19.29 290 11.42 115 4.53 331/52399
Asphalt cutter - 50 1.97 490 19.29 290 11.42 115 4.53 331/52400
transverse
Blunt 50 1.97 510 20.08 310 12.2 - - 331/52398
HM265Q Moil 65 2.56 600 23.62 320 12.6 - - 331/52496
Narrow chisel 65 2.56 600 23.62 320 12.6 - - 331/52497
Wide chisel 65 2.56 650 25.6 370 14.57 125 4.92 331/52498
Wide chisel - 65 2.56 650 25.6 370 14.57 125 4.92 331/52499
transverse
Blunt 65 2.56 600 23.62 320 12.6 80 3.15 331/52500
HM385Q, 386Q Moil 80 3.15 800 31.5 470 18.5 - - 331/52461
Moil 80 3.15 1000 39.37 675 26.57 - - 331/52462
Narrow chisel 80 3.15 800 31.5 470 18.5 - - 331/52464
Wide chisel 80 3.15 770 30.31 445 17.52 160 6.3 331/52467
Wide chisel - 80 3.15 770 30.31 445 17.52 160 6.3 331/52468
transverse
Blunt 80 3.15 800 31.5 470 18.5 - - 331/52493
HM495Q Moil 95 3.74 840 33.07 460 18.11 - - 331/52501
Moil 95 3.74 1200 47.24 820 32.28 - - 331/52502
Narrow chisel 95 3.74 840 33.07 460 18.11 - - 331/52503
Wide chisel 95 3.74 800 31.5 415 16.34 180 7.09 331/52504
Blunt 95 3.74 840 33.07 460 18.11 - - 331/52505
A standard chisel or asphalt cutter is supplied with the cutting face perpendicular to the boom. A parallel chisel or asphalt
cutter has the cutting face parallel with the boom.
A range of steels are available to meet all applications. They are manufactured from high quality materials for long life.
– MOIL: For layered rock and reinforced concrete, where twisting could occur.
– PYRAMID POINT: All moils above 100 mm diameter.
– CHISEL: Standard tool for penetrative work. E.g. Mining, foundations, trenching, demolition.
– BLUNT: For impact breaking. E.g. Mining, breaking oversizes, demolition.
63 9803/1420-04 63
Medium Breakers
Breaker Part Number Matrix
Model Machine Part No.

Rest of World North America
HM165Q 803, 804 980/90237 980/90301
802 980/90253 980/90302
UNIVERSAL 980/90256 980/90303
ROBOT 980/90355 980/90368
1CX 980/90453 N/A
208 N/A 980/90456
MIDI CX 980/90867 980/90868
8020 980/A2706 980/A2731
HM265Q 802 980/90241 980/90304
803, 804 980/90242 980/90305
UNIVERSAL 980/90257 980/90306
3CX RUSSIAN SPECIAL 980/90513 N/A
8052 980/90243 980/90307
8045 980/90286 980/90308
ROBOT 980/90366 980/90309
HM385Q 8052, 8080 980/90238 980/90309
3CX, 4CX 980/90239 980/90310
JZ70 980/90240 980/90311
UNIVERSAL 980/90258 980/90312
ROBOT 980/90367 980/90371
HM386Q 8052, 8080 980/A3477 -
3CX, 4CX 980/A3478 -
JZ70 980/A3480 -
UNIVERSAL 980/A3481 -
ROBOT 980/A3483 -
HM495Q 8080 980/90244 980/90313
3CX, 4CX 980/90245 980/90314
JZ70 980/90246 980/90315
UNIVERSAL 980/90259 980/90316
64 9803/1420-04 64
Service Manual
HM Range Medium and Large Hydraulic

Breakers, Serial Nos. 1095001 onwards
Section 2 Large Breakers
Publication No.
9803/1420-04
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
9803/1420-04
Large Breakers - Contents
Chapter Title Page

Introduction
1 General 1
1.1 Explanation of the symbols in the repair manual 1
Safety
2 Operational safety 2
2.1 General 2
2.2 Accident prevention regulations 2
2.3 Safety Notices 3
Tools
3 Tools 5
3.1 General tools 5
3.2 Service box 6
3.3 Special accessories 7
3.3.1 Accumulator charging device 7
3.3.2 Power wrench 8
3.3.3 HeliCoil-tools 8
3.3.4 Fitting aid for piston 9
3.3.5 Press-out aid for wear bushes 9
3.4 Consumables 10
4 Technical Specifications 11
4.1 Breaker Specifications 11
4.2 Working Pressure/Required Flow/Engine RPM 16
Dismantling
5 Dismantling the Hydraulic Breaker 21
5.1 Fitting/Removing the Tool 21
5.2 Removing the Power Cell from the Hammer Housing 22
5.3 Removing the High-Pressure Accumulator 23
5.4 Removing the Control System 24
5.5 Removing the Control Slide Valve 24
5.6 Removing the Frequency Switching System 25
5.7 Removing the Cylinder Cover 26
5.8 Removing the Piston and sealing Bush 28
5.9 Removing the Cylinder 28
5.10 Removing the Locking Pins for the Retainer Bars in the Lower Breaker Part 29
5.11 Removing the Locking Bushes 29
Checking
6 Checking the Hammer Housing 30
6.1 Checking for Cracks and Indentations 30
i 9803/1420-04 i
Chapter Title Page

6.2 Wear to the Bottom Plate 30
6.3 Checking the Elastic Pad 31
6.4 Checking the Damping Elements 31
6.5 Checking the Guide Plates 32
6.6 Checking the Tool for Wear 33
Assembling
7 Assembling the Hydraulic Hammer 34
7.1 Tightening Torques for Screws and Screw Couplings on the JCB HM 860Q 34
7.6 Tightening Torques for Screws and Screw Couplings on the JCB HM 3060Q and JCB HM 39
4160Q
7.7 Fitting the Cylinder 40
7.8 Fitting the Piston and sealing Bush 40
7.9 Fitting the Cylinder Cover 41
7.10 Fitting the Frequency Switching System 43
7.11 Fitting the Control Slide Valve 44
7.12 Fitting the Control System 44
7.13 Fitting the High-Pressure Accumulator 45
7.14 Checking Pressure in piston Accumulator and Refilling if Required 46
7.15 Fitting the Power Cell into the Hammer Housing 48
7.16 Connecting the JCB AUTOGREASE 49
7.17 Fitting the Tool 50
Changing Seals
8 Changing the Seals 51
8.1 Changing the Cylinder Seals 51
8.2 Changing the Seals between Cylinder and Cylinder Cover 53
8.3 Changing the Seals on the Control System 53
8.4 Changing the Seals on the High Pressure Accumulator 54
8.5 Changing the seals on the Sealing Bush 54
Repair Work
9 Repair Work 55
9.1 Changing the Expansion Bolts on the High-Pressure Accumulator 55
9.2 Changing the High-Pressure Accumulator 55
9.3 Changing the Tie Rods 56
9.4 Removing Scores from Control slide Valve and Bore 57
9.5 Removing Scores on Piston and Cylinder Bore 57
9.6 Changing the Wear Bushes 58
9.7 Replacing the Complete Housing 60
ii 9803/1420-04 ii
Chapter Title Page

9.8 Replacing Guide Plates and Damping Elements in Housing 60
9.9 Repairing Cracked Welds 61
9.10 Replacing the Bottom Plate on the Housing 61
9.11 Reworking the Retainer Pins for the Damping Elements 62
9.12 Weld Seam Preparation 62
9.13 Preheating Temperature 62
9.14 Fillers 62
9.15 Post-treatment of Welds 62
Spares List
10 Spares List 63
10.1 Percussion Unit 63
10.2 Noise Damping 64
10.3 JCB AUTOGREASE 65
Appendices
1 Breaker Operating Principles 67
2 JCB Autogrease Operating Principles 75

11 Nitrogen Adaptor Reference Chart 90
Tool Part Numbers

12 Tool Part Numbers 92

13 Breaker Part Number Matrix 93
iii 9803/1420-04 iii

iv 9803/1420-04 iv
Large Breakers - Introduction
7KHWRROPXVWQRWEHPRGLILHGZLWKRXWWKH
PDQXIDFWXUHU
VSHUPLVVLRQ8VHRQO\RULJLQDOSDUWV
DQGDFFHVVRULHVDSSURYHGE\-&%6HUYLFH,I
PRGLILFDWLRQVDUHPDGHWKDWDUHQRWDSSURYHGE\
-&% 6HUYLFHVHULRXVKDUPWR\RXUVHOYHVRU
RWKHUVPD\UHVXOW
$OOXVHUVRIWKLVLQWUXFWLRQPDQXDODUHDVNHGWRLQIRUP-&%
$WWDFKPHQWVLIWKH\ILQGDQ\HUURUVRUGLVFUHSDQFLHVHVSHFLDOO\
DQ\DIIHFWLQJSURGXFWVDIHW\
6HUYLFH3HUVRQQHO
7KHIROORZLQJLQVWUXFWLRQVDUHLQWHQGHGWRJXLGHVHUYLFH
SHUVRQQHOLQWKHUHSDLURURYHUKDXOLQJRIWKH-&% 7KLVSXEOLFDWLRQLVGHVLJQHGIRUWKHEHQHILWRI-&%
/DUJH%UHDNHUV 'LVWULEXWRU6HUYLFH(QJLQHHUVZKRDUHUHFHLYLQJRU
KDYHUHFHLYHGWUDLQLQJE\WKH-&%7UDLQLQJ&HQWUH
RUE\-&%6HUYLFH3HUVRQQHO7KHVHSHUVRQQHO
VKRXOGKDYHDVRXQGNQRZOHGJHRIZRUNVKRS
SUDFWLFHVDIHW\SURFHGXUHVDQGJHQHUDOWHFKQLTXHV
DVVRFLDWHGZLWKWKHPDLQWHQDQFHDQGUHSDLURI
K\GUDXOLFHTXLSPHQW
5HQHZDORIVHDOVJDVNHWVHWFDQGDQ\FRPSRQHQW
VKRZLQJREYLRXVVLJQVRIZHDURUGDPDJHLV
H[SHFWHGDVDPDWWHURIFRXUVH,WLVH[SHFWHGWKDW
FRPSRQHQWVZLOOEHFOHDQHGDQGOXEULFDWHGZKHUH
-&%+0%UHDNHUVKDYHK\GUDXOLFDOO\SRZHUHG DSSURSULDWHDQGWKDWDQ\RSHQHGKRVHRUSLSH
SHUFXVVLRQPHFKDQLVPV6LQFHDOOK\GUDXOLFDOO\SRZHUHG FRQQHFWLRQVZLOOEHEODQNHGWRSUHYHQWH[FHVVLYH
HTXLSPHQWLVVHQVLWLYHWRGLUWWKHEUHDNHUVPXVWDOZD\V ORVVRIK\GUDXOLFIOXLGDQGLQJUHVVRIGLUW)LQDOO\
EHGLVDVVHPEOHGLQDSODFHWKDWLV SOHDVHUHPHPEHUDERYHDOOHOVH6$)(7<0867
&20(),567
V\PEROV
7KHQXPEHUVHQFORVHGLQEUDFNHWVLQWKHWH[WUHIHUWR
WKHH[SORGHGYLHZRIWKHEUHDNHUVLQ([SORGHG9LHZV
6HFWLRQ
1 9803/1420-04 1
Large Breakers - Safety
2SHUDWLRQDOVDIHW\
'$1*(5
*HQHUDO
7KH EUHDNHU
V LQWHJUDWHGSLVWRQDFFXPXODWRU LV
,QRUGHUWRPDLQWDLQWKHRSHUDWLRQDOVDIHW\RIWKH SUHVVXULVHG
K\GUDXOLF EUHDNHU UHSDLU ZRUN VKRXOGRQO\ EH FDU %HIRUHGLVPDQWOLQJWKHK\GUDXOLFKDPPHUDQGEH
ULHGRXWE\WUDLQHGVSHFLDOLVWVXVLQJJHQXLQHVSDUH IRUHUHPRYLQJWKHFRPSOHWHILOOLQJYDOYH³*´WKH
SDUWV7KLVZRUNVKRXOGWKHUHIRUHRQO\EHHQWUXVWHG SLVWRQDFFXPXODWRUPXVWEHIXOO\GHSUHVVXULVHG
WR VSHFLDOLVWVWUDLQHGE\-&%$WWDFKPHQWV /WG 1HYHUXVHQDLOVVFUHZGULYHUVRUVLPLODUREMHFWVWR
ZKR NQRZ ZKLFK VSDUHSDUWV QHHG UHSODFLQJ EOHHGRIIWKHJDVVLQFHWKLVZRXOGGDPDJHWKHILOO
DQGZKHQ LQJYDOYH%OHHGRIIWKHJDVXVLQJRQO\WKHQR]]OHRI
WKHILOOLQJWHVWKRVH
1HYHUXVH\RXUILQJHUVWRFKHFNWKHDOLJQPHQWRI
$FFLGHQWSUHYHQWLRQ WKHZRUNLQJWRROUHFHVVHVWRWKHREORQJKROHVIRU
UHJXODWLRQV WKHORFNLQJEDUV
1HYHU GLVPDQWOHDK\GUDXOLF EUHDNHU ZKLFKLV VWLOO
KRWIURPUXQQLQJDVWKHUHLVDKLJKULVNRILQMXU\
WKURXJKEXUQV$OZD\VZDLWXQWLOWKHKDPPHUKDV
'$1*(5 FRROHGGRZQEHIRUHGLVPDQWOLQJLW
7RDYRLGWKHSRVVLELOLW\RILQMXU\SOHDVH &ROOHFWDQ\RLOZKLFKUXQVRXWDQGGLVSRVHRILWLQ
REVHUYHWKHIROORZLQJLQVWUXFWLRQV DFFRUGDQFHZLWKWKHDSSOLFDEOHVWDWXWRU\SURYLVLRQV
WRDYRLGHQYLURQPHQWDOKD]DUGV
%HIRUHVWDUWLQJZRUN
3OHDVHIDPLOLDULVH\RXUVHOIZLWKWKHUHSDLUPDQXDO
DQGWKHDSSURSULDWHUHJXODWLRQVEHIRUHVWDUWLQJ '$1*(5
ZRUN RQWKHK\GUDXOLF EUHDNHU
:KHQXVLQJRU ZRUNLQJRQK\GUDXOLF EUHDNHUV LQ 5LVNRIH[SORVLRQ
WKHFRXQWULHVRIWKH(XURSHDQ8QLRQWKHUHJXOD
7KHSLVWRQDFFXPXODWRUPXVWRQO\EHILOOHGZLWKQL
WLRQVRIWKH(&PDFKLQHU\GLUHFWLYH(*PXVW
WURJHQIURPWKHJUHHQF\OLQGHU
EHREVHUYHGDQGIROORZHGDVPXVWQDWLRQDODFFL
0DNHVXUHWKDWQRRWKHUJDVHJDLURUR[\JHQLV
GHQWSUHYHQWLRQUHJXODWLRQVDQGUHJXODWLRQVFRYHU
DOORZHGLQWRWKHSLVWRQDFFXPXODWRU
LQJSUHVVXULVHGYHVVHOV
:KHQDWWDFKLQJWKHKDQJHUEUDFNHW XVHRQO\ WKH
,QFRXQWULHVRXWVLGHWKH(XURSHDQ8QLRQWKHYDOLG
VSHFLDOVWHHO VFUHZV
ORFDOVWDWXWHVDQGUHJXODWLRQVZLOODSSO\
7KHK\GUDXOLF EUHDNHU VKRXOGRQO\ EH UHSDLUHGE\
VSHFLDOLVWV
:KHQOLIWLQJWUDQVSRUWLQJWKHK\GUDXOLF EUHDNHU
XVHRQO\WKHOXJSURYLGHGDQGKRLVWLQJHTXLSPHQW
ZLWKVXIILFLHQWFDSDFLW\
&OHDUKDQGVLJQDOVPXVWEHDJUHHGRQZLWKWKH
KRLVWRSHUDWRUEHIRUHKDQG
1HYHUVWDQGEHQHDWKKRLVWHGORDGV
6WDQGWKHK\GUDXOLF EUHDNHU LQDVXLWDEOHGHYLFH
DQGVHFXUHLWDJDLQVWIDOOLQJRYHU
7KHUHSDLUDUHDPXVWEHFOHDUDQGHDVLO\DFFHVVL
EOH
$OZD\VZHDUSURWHFWLYHJODVVHVZKHQILWWLQJRUUH
PRYLQJWKHZRUNLQJWRROVLQFHPHWDOVSOLQWHUVPD\
IO\RIIZKHQKDPPHULQJRXWWKHORFNLQJSLQV
:RUNLQJWRROVVKRXOGRQO\EHILWWHGDVGHVFULEHGLQ
WKHRSHUDWLQJPDQXDO
2 9803/1420-04 2
2.3 Safety Notices DANGER

Lightning
All mechanical equipment can be hazardous if
Lightning can kill you. Do not use the equipment if
operated without care or correct maintenance.
there is lightning in your area.
In this manual you will find warning messages. Read A-1-3-5
them. Understand them. They tell you of hazards WARNING
and how to avoid them. If you do not understand the Decals
messages, ask your employer or local JCB You can be injured if you do not obey the decal
Distributor. safety instructions. Keep decals clean. Replace
But safety is not just a matter of responding to the unreadable or missing decals with new ones before
warnings. All the time you are working with the operating the machine. Make sure replacement
attachment you must be thinking what hazards there parts include warning decals where necessary.
might be and how to avoid them. INT-1-3-4
Do not work with the attachment until you are sure WARNING
that you can control it.
Equipment Condition
Do not start any job until you are sure that you and Defective equipment can injure you or others. Do not
those around you will be safe. operate equipment which is defective or has missing
If you are unsure of anything, about the machine or parts.
the job, ask someone who knows. Don’t assume Make sure the maintenance procedures in this
anything - check it out. manual are completed before using the equipment.
A-1-4-1
Remember
BE CAREFUL WARNING
BE ALERT The accumulator(s) in the Breaker are pressurised
BE SAFE even when there is no hydraulic pressure to the
breaker. Never tamper with an accumulator.
Now read the rest of this section before moving on Attempting to dismantle an accumulator without first
to the rest of the manual. releasing the pressure can cause injury or death.
B-1-1-2/1
Such work should only be carried out by qualified
servicing personnel who have studied the relevant
Each safety notice starts with a signal word. Service Manual.
The meanings of the signal words are given
below. WARNING
DANGER Modifications and Welding
Non-approved modifications can cause injury and
Denotes an extreme hazard exists. If proper
damage Contact your JCB Dealer for advice before
precautions are not taken, it is highly
modifying the equipment. Before welding on the
probable that the operator (or others) could
Breaker while it is installed on the carrier, disconnect
be killed or seriously injured.
INT-1-2-1
the carrier alternator and battery. Note that electric
welding of the Breaker tools will render them useless
WARNING and make the warranty void.
B-1-3-2/1
Denotes a hazard exists. If proper
precautions are not taken, the operator (or WARNING
others) could be killed or seriously injured.
INT-1-2-2
Protect your ears. Working with the Breaker without
wearing earmuffs can damage your hearing. Wear
CAUTION earmuffs when working with the hammer. Earplugs
Denotes a reminder of safety practices. may be used as an alternative to earmuffs.
B-2-1-11
Failure to follow these safety practices could
result in injury to the operator (or others) and
possible damage to the machine.
INT-1-2-3
3 9803/1420-04 3
! CAUTION !WARNING
Every breaker has its own flow requirement. If the Hydraulic oil at pressure can injure you. Make the
machine is not preset to deliver the correct flow for machine safe as detailed below before removing the
the breaker fitted, either the breaker will not function hose blanking plug. Follow the instructions below for
correctly or the machine may be damaged. connecting the hoses.
8-4-1-3
Whenever a breaker is fitted, it is ESSENTIAL that
the engine speed is correctly preset to suit the !WARNING
breaker.
After the Breaker has been stopped there may be
Have your JCB dealer reset the engine speed before pressure trapped inside it. This pressure could cause
using the machine with a new breaker fitted. This is the Breaker to ‘fire’ unexpectedly and injure you.
a specialist job and the machine can be seriously Before working on the Breaker, take the following
damaged if it is not done correctly. precautions:
a Do not stand in front of the tool.
!CAUTION b Relieve external system pressure by operating
Metal Splinters the relevant controls.
You can be injured by flying metal splinters when
driving metal pins in and out. Use a soft faced c Wait at least 10 minutes, to allow internal
hammer or drift to remove and fit metal pins. Always pressure to decay, before working on the
wear safety glasses. Breaker.
INT-3-1-3
!WARNING
!CAUTION Read this book carefully before operating the
If you have an attachment which is not covered in Breaker for the first time. Protect yourself and others
this handbook do not install it, use it or remove it against flying debris. Wear protective eye glasses
until you have obtained, read and understood the and ear plugs when operating the Breaker. Stop the
pertinent information. Install attachments only on the carrier engine before changing the tool or servicing
machines for which they were designed. the Breaker.
5-5-1-1
!CAUTION !WARNING
Take care when lifting/handling. Refer to
Maintenance work must only be done by competent
SPECIFICATION for the attachment weight.
B-2-1-2/2
personnel.
!CAUTION !WARNING
Equipment Limits Before doing any routine maintenance work on the
Operating the equipment beyond its design limits attachment while it is installed on a carrier, make the
can cause damage. It can also be dangerous. carrier safe. Stop the engine and, if appropriate,
ensure that the parking brake is engaged and the
Do not operate the equipment outside its limits. drive is in neutral. Remove the starter key to prevent
the engine being started.
Do not try to upgrade the equipment’s performance
by unapproved modifications.
A-1-4-2
!WARNING
If two people are doing this job make sure that the
person working the controls is a competent
operator. If the wrong control lever is moved, or if the
controls are moved violently, the other person could
be killed or injured.
2-2-6-5
4 9803/1420-04 4
Large Breakers - Tools
7RROV
*HQHUDOWRROV
7KHWRROVUHTXLUHGIRUUHSDLUZRUNDUHOLVWHGEHORZ
'HVLJQDWLRQ 4W\ -&%3DUW1RV
6OHGJHKDPPHU NJ
6OHGJHKDPPHU NJ
*UHDVHJXQ FSO
6OXJJLQJ ULQJ VSDQQHU VL]H
+HDY\GXW\ ER[ VSDQQHU VL]H
-DZ VSDQQHU VL]H
-DZ VSDQQHU VL]H
-DZ VSDQQHU VL]H
-DZ VSDQQHU VL]H
-DZ VSDQQHU VL]H
-DZ VSDQQHU VL]H
6RFNHW VSDQQHU VL]H
6RFNHW VSDQQHU VL]H
6RFNHW VSDQQHU VL]H
&ODZ VSDQQHU VL]H
$OOHQ NH\ VL]H
$OOHQ NH\ VL]H
$OOHQ NH\ VL]H
$OOHQ NH\ VL]H
$OOHQ NH\ VL]H
$OOHQ NH\ VL]H
3RZHU VFUHZGULYHU LQVHUW VL]Hò´

6FUHZGULYHU PP

$GDSWHU ô³!³³!ò³
7RUTXHZUHQFK 1Pô´
5 9803/1420-04 5
3.2 Service box

The tools required for service work on the breaker
JCB Large Breakers are contained in the Service
box.
Service toolbox and contents can be ordered from

JCB Service.
Item Qty. Designation JCB Part No.

Adapter for See List page
1 1 91/92.
Nitrogen cylinder
2 1 Filler valve 892/01216
3 1 Test pressure gauge 892/01217
4 1 Hose 892/01218
5 1 Pin punch d = 9.5

Pin punch d = 15.5
5 1
L=130
6 1 Allen key
Hexagonal head bolt
7 1 See Note
M 12 x 150
Hexagonal head bolt See Note
8 1
M 20 x 160
Note: The choice of item 7 or 8
is dependant on the size of breaker.
Fig. 1
Service tools
6 9803/1420-04 6
6SHFLDODFFHVVRULHV
7KLVFKDSWHUOLVWVWKHVSHFLDOWRROVDQGDSSDUDWXV
ZKLFK FDQEHSXUFKDVHG IURP -&%6HUYLFH
+ 3 $FFXPXODWRUILOOLQJGHYLFH
7KHWRROVOLVWHGLQWKHWDEOHEHORZDUHXVHGWRILOO
WKHKLJKSUHVVXUHDFFXPXODWRU7KHILOOLQJSURFHVV
DOVRUHTXLUHVWKHQLWURJHQF\OLQGHUDQGWKHILOOHU
YDOYHIURPWKHVHUYLFHER[
'HVLJQDWLRQ
-&%3DUW1R
&KDUJLQJGHYLFH
1LWURJHQERWWOH /
/
)LJ
$FFXPXODWRU FKDUJLQJGHYLFH
7 9803/1420-04 7
3RZHUZUHQFK +HOL&RLOWRROV

<RXFDQFKRRVHEHWZHHQDQHOHFWURQLFRUDK\ 7KHWRROVOLVWHGLQWKHWDEOHEHORZDUHXVHGWRUH
GUDXOLFSRZHUZUHQFK SODFHWKH+HOL&RLOLQVHUWV
'HVLJQDWLRQ -&%3DUW1R ,WHP 'HVLJQDWLRQ 8VH
7%$ 6FUHZWDS
0DQXDO7RUTXH0XOWLSOLHU
0+& &\OLQGHU
(OHFWURQLF7RUTXH0XOWLSOLHU 7%$ 7KUHDGHGLQVHUW
FRYHU
+\GUDXOLF7RUTXH0XOWLSOLHU 0+& &RQWURO
7%$
6FUHZLQWRRO V\VWHP
0+& +LJK
&RQWUROV\VWHP SUHVVXUH
6FUHZLQWRRO DFFXPX
0+& ODWRU

+LJKSUHVVXUH
DFFXPXODWRU
6FUHZWDS

0+&
7KUHDGHGLQVHUW
$GDSWHU
0+&
6FUHZLQWRRO

0+&
)LJ
(OHFWURQLFSRZHUZUHQFK
)LJ
+\GUDXOLFSRZHUZUHQFK
8 9803/1420-04 8
/LIWLQJH\HIRUSLVWRQ
'HVLJQDWLRQ
(\HEROW0
)LJ
)LWWLQJDLG
3UHVVRXWDLGIRUZHDUEXVKHV
,WHP 'HVLJQDWLRQ -&%3DUW1R

3UHVVRXWWRROFRPS
RU
*ULS

6FUHZ

3UHVVRXWHOHPHQWWRS

3UHVVRXWHOHPHQWERWWRP RU
)LJ
3UHVVRXWDLG
9 9803/1420-04 9
&RQVXPDEOHV
8VH &RPPHQWV
+3RLO 5XQQLQJWKH ,QZDUPHUFOLPDWHVRLOVZLWKDKLJKHUYLVFRVLW\FODVVVKRXOGEH
+/3 -&%+0 XVHG
+/3 /DUJH
%UHDNHUV
+LJK 7RRO -&%(3+DPPHU*UHDVH

SHUIRUPDQFH OXEULFDWLRQ JWXEH
JUHDVH
JWXEH
ZLWKVROLGVFRQ
WHQW NJEDUUHO
1LWURJHQ1 )LOOLQJWKH
±KLJK
SUHVVXUH
'$1*(5
DFFXPXODWRU
±SLVWRQ
DFFXPXODWRU
$EUDVLYHSRO 5HPRYLQJ
LVKLQJSDSHU VFRUHV
JUDLQ
10 9803/1420-04 10
Large Breakers - Technical Specifications
4 Technical Specifications
4.1 Breaker Specifications
Model JCB HM 860Q JCB HM 1260Q

Service weight* 850 kg (1875 lb) 1250 kg (2756 lb)
Serial No. from 1095001 on 1095001 on
Recommended carrier class 12 - 18 t (26460 - 39683 lb) 14 - 22 t (30870 - 48510 lb)
Impact rate 420 - 750 blows/min 350 - 600 blows/min
Impact energy (calculated) 1781 Joules 2404 Joules
Dimensions (excluding tool)

Length 1366 mm (54 in) 1579 mm (62 in)
Width 410 mm (16 in) 495 mm (19.5 in)
Depth 560 mm (22 in) 630 mm (25 in)
Oil flow rate 80 - 110 l/min 90 - 120 l/min

(18 - 24 UK gal/min) (20 - 27 UK gal/min)
(22 - 29 US gal/min) (24 - 33 US gal/min)
Operating pressure 140 - 170 bar 140 - 170 bar

(2030 - 2465 psi) (2030 - 2465 psi)
Static pressure
(to be set on A.R.V. for
breaker circuit) 210 bar (2045 psi) 210 bar (2045 psi)
Maximum return line pressure 12 bar (174 psi) 12 bar (174 psi)
Tool diameter 100 mm (3.94 in) 115 mm (4.53 in)
Piston accumulator**
Minimum gas pressure 11 bar (159.5 psi) 5.2 bar (75.4 psi)
Required gas pressure 13.5 bar (195.75 psi) 7 bar (101.5 psi)
Sound pressure level measured

r - 10 m (32.8 ft) 92 LP dB (A) 90 LP dB (A)
Sound power level***

guaranteed 121 LWA dB (A) 120 LWA dB (A)
Connecting thread on ports BSP 3/4” BSP 1”

»P« and »T«
* Hydraulic breaker including breaker housing, tool and medium sized hanger bracket.
** Depending on the oil flow rate.
*** At operating temperature of 60 to 70 ºC (140 to 158 ºF) and no contact pressure to the tool.
**** Measuring process based on directive 2000/14/EC
11 9803/1420-04 11
4.1 Breaker Specifications (continued)
Model JCB HM 1560Q
Service weight* 1600 kg (3527 lb)
Serial No. from 1095001 on
Recommended carrier class 18 - 34 t (39683 - 74957 lb)
Impact rate 360 - 540 blows/min
Impact energy (calculated) 2781 Joules

Length 1664 mm (65.6 in)
Width 495 mm (19.5 in)
Depth 648 mm (25.5 in)
Oil flow rate 130 - 170 l/min

(28.6 - 37.4 UK gal/min)
(34 - 45 US gal/min)
Operating pressure 120 - 140 bar (1740 - 2030 psi)
Static pressure
breaker circuit) 210 bar (3045 psi)
Maximum return line pressure 12 bar (174 psi)
Tool diameter 135 mm (5.32 in)
Minimum gas pressure 5.3 bar (76.85 psi)
Required gas pressure 8.2 bar (118.9 psi)

r - 10 m (32.8 ft) 87 LP dB (A)

guaranteed 117 LWA dB (A)
Connecting thread on ports BSP 1 1/4”

»P« and »T« DIN 2999
12 9803/1420-04 12
Model JCB HM 1760Q

Service weight* 1700 kg (3748.5 lb)
Recommended carrier class 18 - 34t (39683 - 74957 lb)

Length 1827 mm (72 in)

(28.6 - 35.2 UK gal/min)
(34 - 42 US gal/min)
Static pressure
Minimum gas pressure 9.5 bar (137.75 psi)
Required gas pressure 12.3 bar (178.35 psi)

r - 10 m (32.8 ft) 87 LP dB (A)

Connecting thread on ports Flange SAE 1 1/4”

»P« and »T« -6000 psi
13 9803/1420-04 13
Model JCB HM 2460Q JCB HM 3060Q

Service weight* 2150 kg (4741 lb) 3000 kg (6615 lb)
Serial No. from 1095001 on 1095001 on
Recommended carrier class 26 - 40 t (57330 -88200 lb) 32 - 50 t (70560 - 110250 lb)
Impact rate 280 - 550 blows/min 280 - 540 blows/min
Impact energy (calculated) 5400 Joules 7425 Joules

Length 1946 mm (77 in) 2205 mm (87 in)
Width 650 mm (25.6 in) 670 mm (26.4 in)
Depth 700 mm (27.6 in) 800 mm (31.5 in)
Oil flow rate 140 - 180 l/min 210 - 270 l/min

(31 - 40 UK gal/min) (46 - 60 UK gal/min)
(37 - 48 US gal/min) (55 - 72 US gal/min)
Operating pressure 160 - 180 bar 160 - 180 bar

(2320 - 2610 psi) (2320 - 2610 psi)
Static pressure
breaker circuit) 210 bar (3045 psi) 210 bar (3045 psi)
Maximum return line pressure 12 bar (174 psi) 12 bar (174 psi)
Tool diameter 150 mm (6.0 in) 165 mm (6.5 in)
Minimum gas pressure 12 bar (174 psi) 12.5 bar (182 psi)
Required gas pressure 15.5 bar (225 psi) 16 bar (232 psi)

r - 10 m (32.8 ft) 91 LP dB (A) 93 LP dB (A)

guaranteed 121 LWA dB (A) 122 LWA dB (A)
Connecting thread on ports Flange 1 5/8”-12 UNF

»P« and »T« SAE 1 1/4” with JIC cone 37 deg.
-6000 psi
14 9803/1420-04 14
Model JCB HM 4160Q

Service weight* 4120 kg (9085 lb)
Recommended carrier class 42 - 75t (92610 - 165375 lb)

Length 2359 mm (93 in)

(55 - 71 UK gal/min)
(66 - 85 UK gal/min)
Static pressure
Minimum gas pressure 8.6 bar (125 psi)
Required gas pressure 11.5 bar (167 psi)

r - 10 m (32.8 ft) 92 LP dB (A)

Connecting thread on ports 1 5/8-12UNF”

»P« and »T« with JIC cone 37 deg.
15 9803/1420-04 15
4.2 Working Pressure/Required Flow/Engine RPM
JS110
Working
Pressure
(bar) Engine Speed (rpm)
150 1599 1776 1963 2199 -

1487 1653 1851 2086 -
140 1589 1765 1952 2188 -
1476 1647 1845 2081 -
130 1567 1738 1937 2172 -
1466 1637 1835 2070 -
120 1546 1717 1915 2150 -
1450 1621 1819 2054 -
110 1530 1706 1899 2129 2300
1434 1605 1803 2038 2210
70 80 90 100 110
Required Flow (l/min)
***** Upper figure = No load pressure

***** Lower figure = Loaded engine pressure
JS130
Working
Pressure
150 1495 1660 1835 2055 - -

1390 1545 1730 1950 - -
140 1485 1650 1825 2045 2205 -
1380 1540 1725 1945 2110 -
130 1465 1625 1810 2030 2190 -
1370 1530 1715 1935 2100 -
120 1445 1605 1790 2010 2170 -
1355 1515 1700 1920 2080 -
110 1430 1595 1775 1990 2150 2250
1340 1500 1685 1905 2065 2115
70 80 90 100 110 115


16 9803/1420-04 16
4.2 Working Pressure/Required Flow/Engine RPM (continued)
JZ140
Working
Pressure
150 1495 1660 1835 2055 - -

1390 1545 1730 1950 - -
140 1485 1650 1825 2045 2205 -
1380 1540 1725 1945 2110 -
130 1465 1625 1810 2030 2190 -
1370 1530 1715 1935 2100 -
120 1445 1605 1790 2010 2170 -
1355 1515 1700 1920 2080 -
110 1430 1595 1775 1990 2150 2250
1340 1500 1685 1905 2065 2115
70 80 90 100 110 115


JS160/JS180
Working
Pressure
150 1590 1765 1985 2140 2320 -

1480 1660 1875 2045 2210 -
140 1575 1750 1970 2130 2310 -
1470 1655 1870 2035 2215 -
130 1560 1735 1955 2115 2295 -
1460 1645 1860 2025 2205 -
120 1540 1720 1940 2100 2280 -
1445 1630 1850 2020 2195 -
110 1525 1700 1920 2080 2265 2360
1430 1615 1840 2005 2170 2265
80 90 100 110 120 125


17 9803/1420-04 17
JS200/JS220
Working
Pressure
220 1345 1380 1505 1635 1765 1905 2065 - - - - -

1210 1255 1385 1525 1660 1805 1985 - - - - -
200 1320 1340 1410 1535 1650 1780 1925 2040 - - - -
1200 1210 1290 1415 1545 1680 1830 1960 - - - -
180 1290 1330 1335 1455 1555 1690 1805 1930 2055 - - -
1185 1200 1220 1345 1450 1595 1710 1845 1925 - - -
160 1255 1300 1320 1390 1490 1595 1725 1835 1965 2095 - -
1165 1190 1205 1280 1390 1505 1635 1750 1880 2015 - -
140 1135 1255 1305 1340 1440 1540 1650 1765 1880 1985 2095 -
1020 1155 1200 1235 1340 1445 1560 1680 1800 1905 2025 -
120 1075 1190 1290 1300 1400 1490 1590 1690 1800 1905 2015 -
970 1090 1180 1200 1305 1405 1510 1610 1720 1830 1950 -
100 1015 1135 1250 1295 1370 1470 1560 1670 1775 1870 1965 2055
9155 1040 1160 1200 1285 1390 1480 1595 1705 2800 1900 2000
80 955 1070 1195 1280 1365 1460 1560 1660 1765 1860 1955 2040
860 975 1100 1200 1280 1385 1490 1595 1700 1800 1900 1990
80 90 100 110 120 130 140 150 160 170 180 190

JS240/JS260
Working
Pressure
220 1360 1415 1435 1500 1620 1720 1830 1950 - - - -

1170 1190 1205 1275 1400 1520 1640 1765 - - - -
200 1275 1385 1415 1425 1535 1645 1750 18500 1965 2075 - -
1082 1180 1200 1205 1320 1440 1555 1670 1785 1900 - -
180 1180 1320 1375 1410 1450 1560 1670 1770 1870 1990 - -
985 1140 1185 1210 1265 1370 1480 1585 1695 1815 - -
160 1040 1230 1310 1380 1445 1530 1640 1730 1825 2005 2005 -
880 1045 1160 1200 1250 1335 1450 1550 1645 1840 1840 -
140 1130 1145 1250 1340 1395 1495 1605 1700 1790 1880 1975 2075
870 990 1110 1195 1240 1340 1445 1545 1640 1740 1830 1935
120 980 1085 1185 1295 1360 1460 1550 1660 1750 1850 1935 2040
840 955 1060 1175 1230 1330 1425 1525 1625 1725 1815 1920
100 935 1030 1120 1235 1310 1420 1525 1620 1710 1810 1920 2010
820 920 1030 1130 1220 1320 1425 1520 1610 1720 1815 1905
80 910 1010 1100 1195 1285 1370 1475 1590 1680 1785 1885 1970
825 920 1025 1125 1215 1300 1405 1510 1605 1710 1800 1890
80 90 100 110 120 130 140 150 160 170 180 190

18 9803/1420-04 18
JS130W/JS145W
Working
Pressure
150 1495 1660 1835 2055 - -
1390 1545 1730 1950 - -
140 1485 1650 1825 2045 2205 -
1380 1540 1725 1945 2110 -
130 1465 1625 1810 2030 2190 -
1370 1530 1715 1935 2100 -
120 1445 1605 1790 2010 2170 -
1355 1515 1700 1920 2080 -
110 1430 1595 1775 1990 2150 2250
1340 1500 1685 1905 2065 2115
70 80 90 100 110 115


JS160W/JS175W
Working
Pressure
150 1590 1765 1985 2140 2320 -
1480 1660 1875 2045 2210 -
140 1575 1750 1970 2130 2310 -
1470 1655 1870 2035 2215 -
130 1560 1735 1955 2115 2295 -
1460 1645 1860 2025 2205 -
120 1540 1720 1940 2100 2280 -
1445 1630 1850 2020 2195 -
110 1525 1700 1920 2080 2265 2360
1430 1615 1840 2005 2170 2265
80 90 100 110 120 125


19 9803/1420-04 19
JS200W
The hydraulic flow to the breaker on a JS200W machine is controlled by adjusting the servo pressure onto
the end of the hammer spool in the control valve. Refer to the machine service manual for the position of
the hammer spool.
20 9803/1420-04 20
Large Breakers - Dismantling
$ISMANTLINGTHE(YDRAULIC"REAKER
&ITTING2EMOVINGTHE4OOL
)NGENERALTHETOOLISNOTFITTEDWHENTHEBREAKERIS 2EMOVETHERETAINERBARSBYTURNINGASCREWINTOTHE
DELIVERED &OR FITTING MOVE THE BREAKER INTO -THREADPROVIDEDANDUSINGTHESCREWTOPULLOUT
HORIZONTAL POSITION USING THE EXCAVATOR BOOM AND THEBAR
DEPOSITITONASUPPORTEGSQUAREDBEAMS
2EMOVETHEDUSTCAPFROMTHETOOLBOREANDPUTITIN
&ORSAFETYREASONSTHECARRIERMUSTBESWITCHEDOFF THETOOLBOXFORSAFEKEEPING
BEFOREPERFORMINGTHEFOLLOWINGWORK
#LEAN AWAY ANY DIRT ADHERING TO THE TOOL IN THE
#!54)/. INSERTIONZONETHENTHOROUGHLYLUBRICATETHESHAFTOF
THETOOLANDTHEBUSHESWITH*#"!54/'2%!3%
!LWAYS WEAR PROTECTIVE GLASSES WHEN FITTING OR
REMOVING THE TOOL SINCE METAL SPLINTERS MAY FLY OFF 4HERETAINERBARSAREALSOTOBELUBRICATED
WHENHAMMERINGOUTTHELOCKINGPINS
#!54)/.
4OGAINACCESSTOTHELOCKINGPINSREMOVETHEFOUR
SEALINGPLUGS! FITTEDINTHESIDESOFTHEHOUSING .EVERUSEYOURFINGERSTOCHECKTHEALIGNMENTOFTHE
RECESSESINTHEWORKINGTOOLTOTHEOBLONGHOLESFOR
+NOCK THE LOCKING PINS " OUT OF THE LOWER BREAKER THERETAININGBARS
SECTIONUSINGTHEDRIFTCONTAINEDINTHETOOLBOX.OTE
THATTHELOCKINGPINSCANONLYBEBEREMOVEDINONE 4HENINSERTTHETOOLTURNINGITUNTILTHERETAINERBARS
DIRECTION8 SLIDEEASILYINTOTHESLOTS
4O GAIN ACCESS TO THE THE TOOL RETAINER BARS $ 2EPLACETHESEALINGPLUGSANDDRIVETHELOCKINGPINS
REMOVE THE TWO UPPER SEALING PLUGS # FROM THE FORTHERETAINERBARSBACKINTOPOSITION
BREAKER HOUSING AND THE TWO INNER SEALING PLUGS %
FROMTHEPOWERCELL

*

&
2EMOVINGTHE4OOL
2EMOVALOFTHETOOLFORWHATEVERREASONISEFFECTED
INREVERSEORDERTOFITTING
0LEASENOTETHATTHETIPOFTHETOOLMAYREMAINHOT
FORSOMETIMEAFTERUSE
21 9803/1420-04 21
5HPRYLQJWKHSRZHU
FHOOIURPWKHKDPPHU
KRXVLQJ
'$1*(5
v 6WDQGKDPPHUER[ZLWKEUHDNHUYHU
WLFDODQGVHFXUHDJDLQVWIDOOLQJRYHU
)LJ
v 5HPRYHDOOHQVFUHZV)LJXVLQJDOOHQNH\ 8QVFUHZLQJWKHKDQJHUEUDFNHWIURPWKHKRXVLQJ
VL]H)LJDQGUHPRYHWKHKDQJHUEUDFNHW
)LJIURPKRXVLQJXVLQJD
KRLVWFUDQH
v 5HPRYHHODVWLFSDG)LJ
&$87,21
v 5HPRYHJUHDVHRLOOLQHEHWZHHQ-&%$872*5($6(
DQGWKHEUHDNHU
)LJ
v 5HPRYHWKUHDGHGSLQ0 5HPRYLQJWKHHODVWLFSDG
v 6FUHZWZRH\HEROWV0LQWRWKHWZR

WKUHDGHGERUHVRQWKHXSSHUIDFHRIWKHF\OLQ
GHUFRYHUDVIDUDVWKH\ZLOOJR
v 8VLQJDKRLVWFUDQHOLIWWKHSRZHUFHOO
RXWRIWKHEUHDNHU
ER[)LJ
'$1*(5
,IWKHSRZHUFHOOKDVMDPPHGLQWKH )LJ
KDPPHUER[HJGXHWRKHDY\FRQWDPLQDWLRQWKH /LIWLQJWKHSRZHUFHOORXWRIWKHKDP
KRLVWPXVWQRWEHXVHGDVDSXOOLQJGHYLFHZLWKWKH PHUER[
KDPPHUER[KHOGILUPO\
v 6HFXUHWKHEUHDNHUFDVLQJDJDLQVWIDOOLQJRYHU
v 6WDQGWKHSRZHUFHOO
YHUWLFDODQGVHFXUHDJDLQVWIDOOLQJRYHUHJ
SODFHRQDVWDQGVLPLODUWRWKDWLQ)LJ
)LJ
6WDQG
22 9803/1420-04 22
5HPRYLQJWKHKLJKSUHVVXUH
DFFXPXODWRU
v 6WDQGK\GUDXOLFKDPPHUYHUWLFDOO\DQGVHFXUH
DJDLQVWIDOOLQJRYHUHJRQDVWDQGVLPLODUWR
)LJRUOD\IODW
'$1*(5
,IWKHEUHDNHULVVWLOODWWDFKHGWRWKHFDUULHU
WKHK\GUDXOLFV\VWHPPXVWEHGHSUHVVXULVHGSULRU
WRUHPRYLQJWKHKLJKSUHVVXUHDFFXPXODWRU
HJ
v 2QKRVHVZLWKVFUHZFRXSOLQJVUHOLHYHSUHV )LJ
VXUHRQFKHFNYDOYHVDQGGHSUHVVXULVHRSHQ 5HOHDVLQJDQGXQVFUHZLQJWKHH[SDQVLRQEROWV
WKHKRVHSRUWVRQWKHEUHDNHU
v 5HOHDVHH[SDQVLRQEROWV)LJRQDFFX
PXODWRUXVLQJDVL]HVRFNHWVSDQQHU
)LJDQGVFUHZWKHPRXW)LJUH
PRYLQJWKHORFNLQJZDVKHUVDWWKHVDPHWLPH
&$87,21
&ROOHFWDQ\RLOZKLFKUXQVRXWDQGGLVSRVHRILWLQ
DFFRUGDQFHZLWKWKHDSSOLFDEOHVWDWXWRU\SURYLVLRQV
v 5HPRYHKLJKSUHVVXUHDFFXPXODWRU)LJ
v &KHFNWKUHDGHGLQVHUWUHSODFHLI )LJ
QHFHVVDU\ 5HPRYLQJWKHKLJKSUHVVXUHDFFXPXODWRU
&$87,21
7KHKLJKSUHVVXUHDFFXPXODWRUVRQWKHVH
EUHDNHUVKDYHDFDSDFLW\RIODQGODQGDPD[SHU
PLVVLEOHRSHUDWLQJSUHVVXUHRIEDUSVL
v 5HPRYLQJWKH2ULQJDQGEDFNXSULQJ
)LJ
)LJ
5HPRYLQJWKH2ULQJDQGEDFNXSULQJ
23 9803/1420-04 23
5HPRYLQJWKHFRQWUROV\VWHP
v 5HOHDVHH[SDQVLRQEROWV)LJXVLQJD
VRFNHWVSDQQHU)LJDQGVFUHZRXW
UHPRYLQJZDVKHUVDWWKHVDPH
WLPH
v 5HPRYHFRQWUROV\VWHPIURPF\OLQGHU
v 5HPRYHVHDOULQJVIURP
WKHFRQWUROV\VWHP
v &KHFNFRQGLWLRQDQGIXQFWLRQRI+HOL&RLOLQVHUWV
LQF\OLQGHUUHSODFHLIQHFHVVDU\
v &OHDQVHDWIRUFRQWUROV\VWHPRQF\OLQGHU
&$87,21
)LJ
5HPRYLQJWKHFRQWUROV\VWHP
&ROOHFWDQ\RLOZKLFKUXQVRXWDQGGLVSRVHRILWLQ
DFFRUGDQFHZLWKWKHDSSOLFDEOHVWDWXWRU\SURYLVLRQV
5HPRYLQJWKHFRQWUROVOLGH
YDOYH
v 8QVFUHZKH[DJRQDOVRFNHWKHDGVFUHZV
)LJXVLQJDKH[DJRQDOVRFNHW
VFUHZGULYHUUHPRYLQJZDVKHUVDW
WKHVDPHWLPH
v 7DNHRIIFRYHU)LJUHPRYHFRQWUROVOLGH

YDOYH)LJIURPERUHREVHUYLQJGLUHFWLRQ
RIUHPRYDO
)LJ
5HPRYLQJWKHFRQWUROVOLGHYDOYH
24 9803/1420-04 24
5HPRYLQJWKHIUHTXHQF\
VZLWFKLQJV\VWHP
v 6FUHZRXWFRQQHFWLQJVFUHZ)LJXVLQJ
DGRXEOHMDZ VSDQQHU )LJ
)LJ
5HPRYLQJWKHIUHTXHQF\VZLWFKLQJV\VWHP
v 3XOOVSDFHU)LJZLWKVFUHZHGRQYDOYH

EXVKLQJ)LJDQGYDOYHSLVWRQ)LJ 3ODWHVSULQJ
IURPWKHERUH 3RV
v 5HPRYHYDOYHVSULQJ)LJ
1RWH
2EVHUYHSRVLWLRQRISDUWVXSRQUHPRYDO
)LJ
)UHTXHQF\VZLWFKLQJV\VWHP
25 9803/1420-04 25
5HPRYLQJWKHF\OLQGHUFRYHU
'$1*(5
%HIRUHUHPRYLQJWKHF\OLQGHUFRYHUWKHJDVPXVW
EHEOHGIURPWKHSLVWRQDFFXPXODWRU
'RQRWXQVFUHZILOOHUYDOYHIURPF\OLQGHUFRYHUXQ
WLODFFXPXODWRUKDVEHHQGHSUHVVXULVHG
v 8QVFUHZVFUHZSOXJIURPILOOHUYDOYHSRUW³*´ )LJ
XVLQJDQDOOHQNH\)LJ 5HPRYLQJVFUHZSOXJIURPSRUW³*´
v 3XVKQR]]OHRIILOOHUKRVH)LJLQWRILOOHU

YDOYHDQGUHOLHYHSUHVVXUHRQSLVWRQDFFXPXOD
WRU
v 5HPRYHILOOHUYDOYHUHSODFHLIQHFHVVDU\
)LJ
5HOLHYLQJSLVWRQDFFXPXODWRUSUHVVXUH
'$1*(5
5LVNRILQMXU\ZKHQVXSSRUWLQJSRZHUZUHQFK
v 5HOHDVHWLHURGVXVLQJDQHOHFWURQLFK\GUDX
OLFSRZHUZUHQFK)LJDQGXQVFUHZIURP
ORZHUKDPPHUSDUW
1RWH
7LHURGVDQGWKHPDWFKLQJKROHVLQWKHORZHUKDP
PHUSDUWKDYHWREHPDUNHGIRUODWHUUHPRXQWLQJ
v 3XOORXWWLHURGV
)LJ
5HOHDVLQJWLHURGVZLWKDQHOHFWURQLFSRZHUZUHQFK
26 9803/1420-04 26
Or
v Loosen tie rods (Fig. 23/1) if necessary using

the slugging ring spanner (Fig. 23/2) and
sledgehammer (Fig. 23/3).
Note
When using the slugging ring spanner to loosen
the tie rods, the power cell should be laid flat.
Once the tie rods have been loosened, stand the
power cell upright once again.
Fig. 23
Loosening the tie rods
v Screw two eye bolts (M 16) into the threaded

bores on the top of the cylinder cover as far as
they will go and lift off the cylinder cover using
a hoist/crane (Fig. 24).
CAUTION!

Collect any oil which runs out and dispose of it in

accordance with the applicable statutory provisions
to avoid environmental hazards!
Fig. 24
Removing the cylinder cover
27 9803/1420-04 27
5HPRYLQJWKH
SLVWRQDQGVHDOLQJEXVK
v $IWHUUHPRYDORIWKHF\OLQGHUFRYHUVFUHZWKH
ILWWLQJDLG)LJVHHFKDSWHULQWR
WKHWKUHDGHGERUHRQWKHSLVWRQDV
IDUDVLWZLOOJR
v 3XOOWKHSLVWRQ)LJDQGVHDO

LQJEXVK)LJRXWRIWKHF\OLQGHUERUHWR
JHWKHUXVLQJDKRLVWFUDQH
1RWH
5HPRYHWKHSLVWRQLQYHUWLFDOSRVLWLRQ
&$87,21
&ROOHFWDQ\RLOZKLFKUXQVRXWDQGGLVSRVHRILWLQ )LJ
DFFRUGDQFHZLWKWKHDSSOLFDEOHVWDWXWRU\SURYLVLRQV 5HPRYLQJWKHSLVWRQDQGVHDOLQJEXVK
v 6WDQGWKHSLVWRQ)LJXSULJKW

DQGVHFXUHDJDLQVWIDOOLQJRYHU
v 2QFHWKHFUDQHURSHKDVEHHQUHPRYHGIURP
WKHILWWLQJDLG)LJWKHVHDOLQJEXVK
)LJFDQEHSXOOHGRIIWKHSLVWRQ
)LJ
5HPRYLQJWKHF\OLQGHU
v 6FUHZWZRH\HEROWV0LQWRWKHWKUHDGHG
ERUHVRQWKHXSSHUIDFHRIWKHF\OLQGHUDVIDU
DVWKH\ZLOOJR
v /LIWWKHF\OLQGHUIURPWKHORZHUEUHDNHUSDUW
XVLQJDFUDQHKRLVW
)LJ
5HPRYLQJWKHF\OLQGHU
28 9803/1420-04 28
5HPRYLQJWKHORFNLQJSLQV
IRUWKHUHWDLQHUEDUVLQWKH
ORZHUEUHDNHUSDUW
'$1*(5
:HDUSURWHFWLYHJODVVHV
5LVNRILQMXU\IURPIO\LQJPHWDOVSOLQWHUV
v .QRFNRXWORFNLQJSLQXVLQJWKH
SLQSXQFKDQGDKDQGKDPPHU)LJ
)LJ
.QRFNLQJRXWWKHORFNLQJSLQ
5HPRYLQJWKHORFNLQJ
EXVKHV
v ,QVHUWDVFUHZGULYHUEHKLQGWKHORFNLQJEXVK
)LJ
v 8VHWKHVFUHZGULYHUWROHYHUWKHORFNLQJEXVK
RXWRIWKHERUH7KHEXVKPXVWEHUHSODFHGLI
WKHORFNLQJSLQFDQEHSXVKHGRXWRIWKHERUH
E\SUHVVLQJRQLWILUPO\ZLWKDILQJHU
)LJ
5HPRYLQJWKHORFNLQJEXVK
29 9803/1420-04 29
Large Breakers - Checking
&KHFNLQJWKHKDPPHU
KRXVLQJ
&KHFNLQJIRUFUDFNVDQG
LQGHQWDWLRQV
&KHFNWKHFRPSOHWHKRXVLQJIRUFUDFNVZKLFK
PD\EHFDXVHGLIWKHPDWHULDOLVRYHUVWUHVVHGIUH
TXHQWO\DVDUHVXOWRIPHWDOOLFFRQWDFWEHWZHHQWKH
SRZHUFHOODQGWKHKDPPHUKRXVLQJ )LJ
,QGHQWDWLRQDWGDPSLQJHOHPHQWEHDULQJSRLQWV
$VVKRZQLQWKHILJXUHVRQWKHULJKWFRQWDFWEH
WZHHQKDPPHUDQGKRXVLQJDWWKHVHSRLQWV
FDQFDXVHLQGHQWDWLRQVDQGPDUNV
7KHFDXVHLVZHDUWRWKHJXLGHSODWHVLQWKHORZHU
]RQHZKLFKDOORZVJUHDWHUIUHHGRPRIPRYHPHQW
LQWKHXSSHU]RQHOHDGLQJWRFRQWDFWZLWKWKHKDP
PHUKRXVLQJ
&KHFNWKHJXLGHSODWHVIRUZHDU
1RWH-&%UHFRPPHQG5RFROFUDFNGHWHFWLRQNLWV
)LJ
,QGHQWDWLRQRQLQWHUPHGLDWHSODWHKLJKSUHVVXUHDF
IRUWKLVSXUSRVH&RQWDFWZZZURFROFRP
FXPXODWRU
:HDUWRWKHERWWRPSODWH
)UHTXHQWO\UHSHDWHGFRQWDFWZLWKWKHPDWHULDOEH
LQJEURNHQUHVXOWVLQVHULRXVZHDUWRWKHERWWRP
SODWH7RDYRLGKDYLQJWRUHSODFHWKHFRPSOHWH
KDPPHUKRXVLQJLQVXFKFDVHVWKHUHDUHWZRSRVVLEOH
UHPHGLHV
v 5HSODFHPHQWRIFRPSOHWHERWWRPSODWHVHH

1HZERWWRPSODWHVFDQEHSXUFKDVHGIURP
-&%6HUYLFH
v ,QVSHFLDOFDVHVWKHZRUQERWWRPSODWHFDQEH
UHSDLUHGE\EXLOGXSZHOGLQJ
)LJ
:RUQERWWRPSODWH
30 9803/1420-04 30
&KHFNLQJWKHHODVWLFSDG
2QFHWKHKDQJHUEUDFNHWKDVEHHQUHPRYHGWKHHODVWLF
SDGFDQEHWDNHQRXWDQGVXEMHFWHGWRDYLVXDODQG
GLPHQVLRQDOFKHFN
7KHILJXUHRQWKHULJKWVKRZVWKHFKHFNGLPHQVLRQ
´K´7KLVGLPHQVLRQLVUHGXFHGWKHORQJHUWKHSDGLV H
XVHGHLWKHUGXHWRWKHPDWHULDOVHWWOLQJRUGXHWR
ZHDUWKURXJKUHODWLYHPRYHPHQW$IWHUDVHUYLFH
OLIHRIDSSUR[±RSHUDWLQJKRXUVGLPHQ
VLRQ´K´PD\IDOOEHORZLWVORZHUOLPLWDWZKLFKSRLQW
WKHHODVWLFSDGPXVWEHUHSODFHG
(ODVWLF3DGGLPHQVLRQV
0RGHO 'LPHQVLRQ³K´
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN 1RWFKHVGXHWRFUDFNLQJ
7KHVDPHILJXUHDOVRVKRZVWKHHIIHFWVRIH[FHV )LJ
VLYHFRQWDFWSUHVVXUHRQWKHKDPPHUGXULQJXVH &KHFNGLPHQVLRQ´K´DQGFUDFNVQRWFKHVLQWKH
:KHQFRQWDFWSUHVVXUHLVWRRKLJKWKHPDWHULDORI HODVWLFSDG
WKHHODVWLFSDGIORZVRYHUWKHHGJHVRIWKHXSSHU
KDPPHUSDUWFDXVLQJWKHPDWHULDOWRFUDFNDQG
OHDYLQJQRWFKHV
$VWLPHJRHVRQWKHVHQRWFKHVJHWELJJHUDQGFDQ
FDXVHODUJHUSLHFHVRIWKHHODVWLFSDGWREUHDNRII
RUOHDGWRGHHSFUDFNV
&KHFNLQJWKHGDPSLQJ H
HOHPHQWV
+HUHDJDLQH[FHVVLYHORDGVPD\FDXVH
FUDFNVQRWFKHVZKLFKWKHQQHFHVVLWDWHUHSODFH
PHQWLQSDLUV
7KHFKHFNGLPHQVLRQ´K´VKRXOGDOVREHPHDVXUHG
XSRQGLVPDQWOLQJWRGHFLGHZKHWKHUUHSODFHPHQWLQ
SDLUVLVQHFHVVDU\7KHWDEOHVKRZVWKHORZHUOLPLW
IRUWKHFKHFNGLPHQVLRQ´K´
'DPSLQJ(OHPHQWV 1RWFKHVGXHWRFUDFNLQJ
(-1 MMIN
(-1 MMIN
)LJ
(-1 MMIN
&KHFNGLPHQVLRQ´K´DQGFUDFNVQRWFKHVRQWKH
(-1 MMIN GDPSLQJHOHPHQW
(-1 MMIN
(-1 MMIN
(-1 MMIN

31 9803/1420-04 31
&KHFNLQJWKHJXLGHSODWHV
7KHJXLGHSODWHVDUHVXEMHFWWRZHDUGXULQJQRUPDO
XVH7KHSHQHWUDWLRQRIGXVWDQGGLUWDORQJZLWK $EUDVLRQ
VXUIDFHSUHVVXUHFDXVHKHDY\DEUDVLRQWRWKH
&RQFKRLGDO
SODWHV
IUDFWXUH
)LJVKRZVIXUWKHUSRVVLEOHZHDUDQGGDPDJH
'HSHQGLQJRQFRQGLWLRQWKHJXLGHSODWHVVKRXOGEH
UHSODFHGLQGLYLGXDOO\RULQVHWV
&UDFNV
%\PHDVXULQJWKHWKLFNQHVVRIWKHSODWHVLWLVSRV
VLEOHWRGHWHUPLQHZKHWKHUUHSODFHPHQWFDQEH
SRVWSRQHGE\LQVHUWLQJWKLQVKHHWVDVVKLPV
)LJ 'LUW
GHSRVLWV
:KHQVKLPPLQJLQWKLVZD\DVKHHWDWOHDVWRQH
PPWKLFNPXVWEHLQVHUWHGRQHDFKVLGH
$EUDVLRQ
)LJ
&$87,21 3RVVLEOHZHDUDQGGDPDJHWRWKHJXLGHSODWHV
6HUYLFHRSHQLQJVPXVWUHPDLQDFFHVVLEOH
7KHWDEOHVKRZVWKHUHIHUHQFHWKLFNQHVVRIWKH
JXLGHSODWHV
:DOORI
*XLGH3ODWHV
KDPPHU
ER[
(-1 MMIN 6KLP
(-1 MMIN
(-1 MMIN
(-1 MMIN *XLGH
(-1 MMIN SODWH
(-1 MMIN
(-1 MMIN
1RWH
3ODWHWKLFNQHVVLVPRVWO\RQO\ZHDUUHGXFHGORFDOO\
$GHFLVLRQRQZKHWKHUWRUHSODFHWKHJXLGHSODWHV
WKHUHIRUHGHSHQGVRQWKHJHQHUDOFRQGLWLRQRIWKH
SDUWVLQHDFKFDVH )LJ
&KHFNGLPHQVLRQ´K´DQGDUUDQJHPHQWRIVKLPV
32 9803/1420-04 32
#HECKINGTHE4OOLFORW EAR
#HECK THE TOOL FOR WEAR EACH TIME THE TOOL IS
CHANGEDANDATTHELATESTAFTEROPERATINGHOURS
)FTHESHAFTOFTHETOOLHASWORNDOWNTOBELOWTHE
PERMISSIBLEMINIMUM
!NYBURRINGONTHETOOLMUSTBESMOOTHED
OFFCAREFULLY
4HE INSIDE DIAMETER OF THE LOWER WEAR BUSH HAS TO
-ODEL -INIMUMDIAMETER$
'
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
(-1 MMIN
BE CHECKED EVERY TIME THE TOOL IS CHANGED AND AT

THELATESTEVERYOPERATINGHOURS
#HECKINGTHE7EAR"USHESAND"UFFER2ING
)FTHEDIAMETERHASENLARGEDDUETOWEARTHEWEAR
BUSHMUSTBEREPLACED -ODEL TEMPLATE -AX
PERMISSIBLE
7HENTHELOWERWEARBUSHINGISREPLACEDTHEINSIDE DIAMETER
DIAMETER OF THE UPPER WEAR BUSHING MUST BE
(-1 MMIN MMIN
CHECKED
(- 1 MMIN MMIN
)FTHEDIAMETERHASENLARGEDDUETOWEARTHEWEAR
BUSHANDTHEBUFFERRINGMUSTBEREPLACED0LEASE (-1 MMIN MMIN
CONTACTYOUR*#"$EALER
(-1 MMIN MMIN
! PLASTIC TEMPLATE IS SUPPLIED WITH THE BREAKER TO
CHECK THE INSIDE DIAMETER WHICH MUST NOT EXCEED (- 1 MMIN MMIN
THEMAXIMUMDIMENSIONINDICATEDINTHETABLE
(-1 MMIN MMIN
(-1 MMIN MMIN
0LASTIC4EMPLATE *#"0ART.O
(-14OOL'AUGE
(-14OOL'AUGE
(-14OOL'AUGE
(-14OOL'AUGE
(-14OOL'AUGE
(- 14OOL'AUGE
(-14OOL'AUGE
33 9803/1420-04 33
Large Breakers - Assembling
$VVHPEOLQJWKHK\GUDXOLFKDPPHU
7LJKWHQLQJWRUTXHVIRUVFUHZVDQGVFUHZ FRXSOLQJVRQWKH
-&%+04
&RQQHFWLRQSRLQW 7RROVL]HLQPP 7LJKWHQLQJWRUTXH

+DQJHUEUDFNHW $OOHQNH\VL]HPP 1P
7LHURGV 6OXJJLQJULQJVSDQQHU 3UHWLJKWHQQXWVLQGLDJRQDOO\RS
VL]HPP SRVHGSDLUVWR1P
7KHQWLJKWHQLQGLDJRQDOO\RSSRVHG
SDLUVE\DIXUWKHUVLGHVRI
KH[DJRQDOKHDG
7KHQILQLVKWLJKWHQLQGLDJRQDOO\RS
SRVHGSDLUVE\òVLGHVRI
KH[DJRQDOKHDG
6WHS
1P
6WHS

6WHS

+RVHFRQQHFWLRQV 6RFNHWDQGMDZVSDQQHUV
-&%$872*5($6( RIYDU\LQJVL]HV
3RUWV3DQG7 -DZVSDQQHUVL]HPP 1P
)LOOLQJYDOYH* 6RFNHWVSDQQHUVL]HPP 1P

6FUHZSOXJ $OOHQNH\VL]HPP 1P
34 9803/1420-04 34

-&%+04

+DQJHUEUDFNHW $OOHQNH\PP 1P
7LHURGV 6OXJJLQJULQJVSDQQHUPP v 3UHWLJKWHQQXWVLQGLDJRQDOO\
RSSRVHGSDLUVWR1P
v 7KHQWLJKWHQLQGLDJRQDOO\
RSSRVHGSDLUVE\DIXUWKHU
VLGHVRIKH[DJRQDOKHDG
v 7KHQILQLVKWLJKWHQLQGLDJRQDOO\
RSSRVHGSDLUVE\VLGHV
RIKH[DJRQDOKHDG
6WHS 6WHS
1P

6WHS

$OOHQVFUHZKH[VFUHZ $OOHQNH\PP 1P

9DOYHFRYHUFRQWUROYDOYH
3RUWV3DQG7 -DZVSDQQHUPP 1P
)LOOLQJYDOYH* 6RFNHWVSDQQHUPP 1P

6FUHZSOXJ $OOHQNH\PP 1P
+LJKSUHVVXUH $OOHQNH\PP 1P
DFFXPXODWRU
35 9803/1420-04 35
7LJKWHQLQJWRUTXHVIRUVFUHZVDQGVFUHZFRXSOLQJVRQWKH
-&%+04

7LHURGV 6OXJJLQJULQJVSDQQHU v 3UHWLJKWHQQXWVLQGLDJRQDOO\
VL]HPP RSSRVHGSDLUVWR1P
v 7KHQWLJKWHQLQGLDJRQDOO\RS
SRVHGSDLUVE\DIXUWKHU
v
7KHQILQLVKWLJKWHQLQGLDJRQDOO\
RSSRVHGSDLUVE\òVLGHV
RIKH[DJRQDOKHDG
6WHS 6WHS
1P
6WHS

([SDQVLRQVEROWV 6RFNHWVSDQQHUVL]HPP 1P

&RQWUROV\VWHP

&RQWL/XEH ,, RIYDU\LQJVL]HV

IUHTXHQF\ 6RFNHWVSDQQHUVL]HPP 1P
VZLWFKLQJV\VWHP)
+LJKSUHVVXUH 6RFNHWVSDQQHUVL]HPP
DFFXPXODWRU

7UHDWWKHWKUHDGVDQG+HOL&RLOWKUHDGLQVHUWVIRUWKHUHGXFHGVKDIWEROWVZLWKDQDQWLVHL]HDJHQW
7UHDWWKHVXUIDFHVEHWZHHQWKHEROWKHDGZDVKHUDQGKLJKSUHVVXUHDFFXPXODWRUFRYHUZLWKDQWL
VHL]H
3ODFHRQWKHKLJKSUHVVXUHDFFXPXODWRUDQGWLJKWHQWKHDQWLIDWLJXHEROWVE\KDQGLQDFURVVZLVH
IDVKLRQ
3UHWLJKWHQWKHUHGXFHGVKDIWEROWVWR1PSURFHHGLQJLQDFURVVZLVHIDVKLRQ
WKHQWLJKWHQHDFKEROWWKURXJKLQDFURVVZLVHIDVKLRQ
ILQDOO\WLJKWHQHDFKEROWDJDLQWKURXJKLQDFURVVZLVHIDVKLRQ
36 9803/1420-04 36

-&%+04

7LHURGV 6OXJJLQJULQJVSDQQHU v 3UHWLJKWHQQXWVLQGLDJRQDOO\RS
VL]HPP SRVHGSDLUVWR1P
SRVHGSDLUVE\DIXUWKHU
RSSRVHGSDLUVE\
òVLGHVRIKH[DJRQDOKHDG
6WHS 6WHS
1P
6WHS

$OOHQVFUHZKH[VFUHZ $OOHQNH\VL]HPP 1P


+LJKSUHVVXUH $OOHQNH\VL]HPP 1P
DFFXPXODWRU
37 9803/1420-04 37

-&%+04

7LHURGV 6OXJJLQJULQJVSDQQHU v 3UHWLJKWHQQXWVLQGLDJRQDOO\
VL]HPP RSSRVHGSDLUVWR1P
v
7KHQWLJKWHQLQGLDJRQDOO\
RSSRVHGSDLUVE\DIXUWKHU
RSSRVHGSDLUVE\VLGHV
RIKH[DJRQDOKHDG
6WHS 6WHS
1P
6WHS

$OOHQVFUHZKH[VFUHZ $OOHQNH\VL]HPP 1P

-&% $872*5($6( RIYDU\LQJVL]HV
+LJKSUHVVXUH $OOHQNH\VL]HPP 1P
DFFXPXODWRU
38 9803/1420-04 38
7LJKWHQLQJWRUTXHVIRUVFUHZV DQG VFUHZ FRXSOLQJV RQ WKH

-&%+04DQG-&%+04
7LHURGV -&%+04 v 3UHWLJKWHQQXWVLQGLDJRQDOO\
6OXJJLQJULQJVSDQQHU RSSRVHGSDLUVWR1P
VL]HPP
-&%+04 SRVHGSDLUVE\DIXUWKHU
6OXJJLQJULQJVSDQQHU VLGHVRIKH[DJRQDOKHDG
VL]HPP
RSSRVHGSDLUVE\VLGHV
RIKH[DJRQDOKHDG
6WHS 6WHS
1P
6WHS

$OOHQVFUHZ $OOHQNH\VL]HPP 1P

-&% $872*5($6( RIYDU\LQJVL]HV
+LJKSUHVVXUH
DFFXPXODWRU $OOHQNH\VL]HPP 6HH
-&%+04DQG-&%+04
7UHDWWKHWKUHDGVDQG+HOL&RLOWKUHDGLQVHUWVIRUWKHUHGXFHGVKDIWEROWVZLWKDQDQWLVHL]HDJHQW
7UHDWWKHVXUIDFHVEHWZHHQWKHEROWKHDGVWKHZDVKHUVDQGKLJKSUHVVXUHDFFXPXODWRUFRYHUZLWK
DQWLVHL]H
3ODFHRQWKHKLJKSUHVVXUHDFFXPXODWRUDQGWLJKWHQWKHDQWLIDWLJXHEROWVE\KDQGLQDFURVVZLVHIDVKLRQ
3UHWLJKWHQWKHUHGXFHGVKDIWEROWVWR1PSURFHHGLQJLQDFURVVZLVHIDVKLRQ
WKHQWLJKWHQHDFKEROWWKURXJKLQDFURVVZLVHIDVKLRQ
ILQDOO\WLJKWHQHDFKEROWDJDLQWKURXJKLQDFURVVZLVHIDVKLRQ
39 9803/1420-04 39
)LWWLQJWKHF\OLQGHU
v &OHDQFRQWDFWIDFHVRQORZHUKDPPHUSDUW
)LJDQGF\OLQGHU)LJ
v ,QVHUWVHDOLQJULQJ)LJZLWK

-&%(3+DPPHU*UHDVH
LQWKHUHFHVVRQWKHXSSHUIDFHRIWKHORZHU
KDPPHUSDUW
v 3RVLWLRQWKHF\OLQGHU)LJRQWKHORZHU

KDPPHUSDUW)LJXVLQJDKRLVWFUDQH
DQGDOLJQWKHWLHURGERUHV
v 5HPRYHH\HEROWV)LJIURPWKHF\OLQGHU
)LJ
)LWWLQJWKHF\OLQGHU
)LWWLQJWKHSLVWRQ
DQGVHDOLQJEXVK
v &OHDQSLVWRQ)LJDQGFRDW
ZLWKK\GUDXOLFRLO
v 8VLQJDFUDQHKRLVWLQVHUWSLVWRQ
)LJLQWRF\OLQGHUDVIDUDVLWZLOOJR
v 5HPRYHILWWLQJDLG)LJIURP

SLVWRQ)LJ
v 6OLGHVHDOLQJEXVK)LJRQWR

SLVWRQ)LJ
v )LWVHDOLQJEXVK)LJLQWRF\OLQGHUXVLQJ

DUXEEHUPDOOHW
1RWH
$OZD\VXVHVHDOLQJEXVKZLWKQHZVHDOVDQGRE
VHUYHILWWLQJGLUHFWLRQIRUEXVKVHH )LJ
)LWWLQJWKHVHDOLQJEXVK
40 9803/1420-04 40
)LWWLQJWKHF\OLQGHUFRYHU
v &OHDQFRQWDFWIDFHVRIF\OLQGHUDQGF\OLQGHU
FRYHU
v %HIRUHILWWLQJJUHDVH2ULQJZLWK-&%
(3+DPPHU*UHDVH
v ,QVHUW2ULQJ)LJ
)LJ
)LWWLQJWKH2ULQJ
v %HIRUHLQVHUWLQJLQWKHUHFHVVHVLQWKHF\OLQGHU
IDFHFRDWVHDOLQJULQJV)LJ
EHWZHHQF\OLQGHU)LJDQGF\OLQ
GHUFRYHU)LJZLWK-&%(3
+DPPHU*UHDVHDQGORFDWH

v 8VLQJDKRLVWFUDQHSODFHF\OLQGHUFRYHURQ
F\OLQGHUDQGORFDWHWKURXJKERUHVIRUWLHURGV
ORFNLQJSLQ
v 5HPRYHH\HEROWVIURPF\OLQGHUFRYHU
&$87,21
)LJ
:DVKHUV)LJDUHFRQLFDORQRQHVLGH:KHQ
)LWWLQJWKHF\OLQGHUFRYHU
ILWWLQJZDVKHUVFRQLFDOVLGHPXVWEHIDFLQJKHDGRI
WLHURG)LJ
v 7UHDWWKHWKUHDGVRIWKHWLHURGVZLWKDQWLVHL]H
DJHQW
v 3URYLGHWLHURGV)LJZLWKRQHZDVKHU

HDFK)LJDQGLQVHUWLQWKHERUH
v 6FUHZWLHURGVLQWRWKUHDGLQORZHUKDPPHU
SDUW
v 5HPHPEHUWRILWWKHWLHURGVLQWKHVDPHORFDWLRQ
DVZKHQUHPRYHG
)LJ
)LWWLQJWKHWLHURGV
41 9803/1420-04 41
v 8VLQJDWRUTXHZUHQFKSUHWLJKWHQWLHURGVLQ
RSSRVLQJSDLUVWLJKWHQLQJWRUTXHVVHHFKDSWHU
WR
'$1*(5
5LVNRILQMXU\WKURXJKSRZHUZUHQFKVXSSRUW
v 7KHQILQLVKWLJKWHQLQRSSRVLQJSDLUVLQWZR
VWHSVXVLQJDQHOHFWURQLFK\GUDXOLFSRZHU
ZUHQFK)LJWXUQLQJDQJOHVVHHFKDS
WHUWR
)LJ
7LJKWHQLQJWLHURGVZLWKDQHOHFWURQLFSRZHUZUHQFK
RU
v 7LJKWHQWLHURGVLQWZRVWHSVLQRSSRVLQJSDLUV
XVLQJVOXJJLQJULQJVSDQQHU)LJDQG
VOHGJHKDPPHU)LJWHPSRUDULO\OD\WKH
EUHDNHUIODWIRUWKLV
)RUWXUQLQJDQJOHVHHWR
v :KHQWKLVVWDJHLVFRPSOHWHGUHWXUQWKHEUHDNHU
WRWKHYHUWLFDOSRVLWLRQWRFRPSOHWHWKHUHEXLOG
&$87,21
$IWHUDVVHPEOLQJWKHSRZHUFHOOWKH
SLVWRQDFFXPXODWRUPXVWEHILOOHGZLWKQLWURJHQ

VHH
)LJ
7LJKWHQLQJWLHURGV
42 9803/1420-04 42
)LWWLQJWKHIUHTXHQF\
VZLWFKLQJV\VWHP
v ,QVHUWSUHVVXUHVSULQJ)LJLQ
FRUUHVSRQGLQJERUHRQF\OLQGHUFRYHU³)´
VHH
v *UHDVHQHZ2ULQJ)LJZLWK-&% 3ODWHVSULQJ
(3+DPPHU*UHDVHDQGSODFHRQYDOYH 3RV
EXVK)LJ
v )LWYDOYHSLVWRQ)LJLQERUHRIYDOYH

EXVK)LJREVHUYLQJGLUHFWLRQRIUH
PRYDO
v 6FUHZVSDFHU)LJDQGYDOYHEXVK

)LJWRJHWKHUDQGLQVHUWLQWKHF\OLQGHU
FRYHUERUH
v )LWSODWHVSULQJV)LJREVHUYLQJGLUHF

WLRQRIUHPRYDO
v 3URYLGHFRQQHFWLRQVFUHZ)LJZLWKQHZ

2ULQJ)LJDQGVFUHZLQWRERUH3ULRUWR
WKLVOXEULFDWH2ULQJZLWK-&%(3+DPPHU
*UHDVH
)LJ
)LWWLQJIUHTXHQF\VZLWFKLQJV\VWHP
43 9803/1420-04 43
)LWWLQJWKHFRQWUROVOLGH
YDOYH
v /XEULFDWHFRQWUROVOLGHYDOYH)LJZLWK
K\GUDXOLFRLO
v )LWFRQWUROVOLGHYDOYH)LJLQERUHLQFRQ

WUROFDVLQJFRYHU
v (QVXUHYDOYHLVILWWHGWKHULJKWZD\URXQG
&$87,21
:KHQILWWLQJWKHFRQWUROFDVLQJFRYHUDOZD\VXVH
QHZ2ULQJV
v *UHDVH2ULQJZLWK-&%(3+DPPHU*UHDVH
v 6FUHZWKHWZRDOOHQVFUHZV0RXWRIFRQWURO
FDVLQJFRYHU)LJDQGILWFRYHUHQVXULQJ
LWLVVWUDLJKWDQGQRWWLOWHG )LJ
)LWWLQJWKHFRQWUROVOLGHYDOYH
v )DVWHQFRQWUROFDVLQJFRYHU)LJZLWKDO
OHQVFUHZV)LJDQGWLJKWHQLQRSSRVLQJ
SDLUVZLWKVL]HDOOHQNH\)LJ
7LJKWHQLQJWRUTXHVHHWR
)LWWLQJWKHFRQWUROV\VWHP
v /XEULFDWHVHDOLQJULQJV)LJ
DQG)LJZLWK-&%(3
+DPPHU*UHDVHDQGLQVHUWLQWRIURQWIDFH
RIFRQWUROV\VWHP
v $WWDFKFRQWUROV\VWHPWRF\OLQGHUORFDWHXVLQJ
VSULQJGRZHOVOHHYHDQGIL[XVLQJH[SDQVLRQ
EROWV)LJDQGZDVKHUV
)LJ
2EVHUYHWLJKWHQLQJWRUTXHVHHWR
)LJ
)LWWLQJWKHFRQWUROV\VWHP
44 9803/1420-04 44
)LWWLQJWKHKLJKSUHVVXUH
DFFXPXODWRU
&$87,21
:KHQILWWLQJWKHFRQWUROFDVLQJFRYHUDOZD\VXVH
QHZ2ULQJDQGEDFNXSULQJ
v )LW2ULQJ)LJDQGEDFNXS

ULQJ)LJRQKLJKSUHVVXUH
DFFXPXODWRU/RFDWHZLWK-&%(3+DPPHU*UHDVH
)LJ
)LWWLQJWKHKLJKSUHVVXUHDFFXPXODWRU
v )LWKLJKSUHVVXUHDFFXPXODWRUWRF\OLQGHUFRYHU
)LJ
v 7UHDWWKHWKUHDGVRIWKHH[SDQVLRQEROWVZLWK
DQWLVHL]HDJHQW
v 3ODFHORFNLQJZDVKHUVRQH[SDQ
VLRQEROWVDQGVFUHZWKHPWKURXJK
WKHERUHVLQWKHDFFXPXODWRULQWRWKHWKUHDGHG
ERUHVLQWKHF\OLQGHUFRYHU
)LJ
)LWWLQJWKHKLJKSUHVVXUHDFFXPXODWRU
v 7LJKWHQH[SDQVLRQEROWVXVLQJDVL]HVRFNHW
VSDQQHU)LJ
&$87,21
([SDQVLRQEROWVPXVWEHWLJKWHQHGLQRSSRVLQJ
SDLUVWRWKHUHTXLUHGWRUTXHWLJKWHQLQJWRUTXHVHH
WR
)LJ
7LJKWHQLQJWKHKLJKSUHVVXUHDFFXPXODWRU
45 9803/1420-04 45
#HECKING0RESSUREIN0ISTON!CCUMULATORAND2EFILLINGIF2EQUIRED
4HESEITEMSSHOULDBEONHANDATALLTIMESTOALLOW &ILLINGREFILLING
THEFOLLOWINGCHECKINGANDMAINTENANCEWORKTOBE !LLTOOLSANDPARTSREQUIREDFORFILLINGARECONTAINED
PERFORMED INTHETOOLBOX
NITROGENFILLINGDEVICE 0REPARATIONS
PRESSUREGAUGEIN BARTESTCLASS
NITROGENCYLINDER #ONNECTTHEPRESSURERELIEFVALVETOTHENITROGEN
0ARTS.OS#OMPLETEKITAND CYLINDER
#HECKING #ONNECT ONE NOZZLE OF THE FILLING HOSE TO THE
-INI MESSPORTONTHEPRESSURERELIEFVALVE
)FTHEPERFORMANCEOFTHEHYDRAULICBREAKERSTARTSTO
DROP THE GAS PRESSURE IN THE BREAKERS PISTON #LOSETHEPRESSURE RELIEFVALVE
ACCUMULATOR SHOULD BE CHECKED 4HE PISTON /PENTHEVALVEONTHENITROGENCYLINDER
ACCUMULATOR DOES NOT NEED TO BE REFILLED UNTIL THE
GASPRESSUREHASDROPPEDTOTHEMINIMUMLEVELOR 5NSCREWTHEPLUGFROMFILLINGVALVEw'i
BELOW 0RESSTHEFREENOZZLEONTHEFILLINGHOSEINTOTHE
.OTE 4HE PRESSURE SHOULD BE CHECKED AFTER THE FILLINGVALVEw'i
BREAKER HAS REACHED AN OPERATING TEMPERATURE OF
ª#TOª#ª&TOª& $&&808/$725
,AYTHEHYDRAULICBREAKERFLATTOCHECKTHEPRESSURE
$ONOTAPPLYCONTACTPRESSURETOTHETOOL
5NSCREWTHEPLUGFROMFILLINGVALVEw'iANDCONNECT
UPTHEPRESSUREGAUGE
2EADOFFTHEPRESSURE
4HE REQUIRED PRESSURE IN THE PISTON ACCUMULATOR IS
ASFOLLOWS
ATOPERATINGPRESSURE ª#
ª&NOCONTACTPRESSURE
TOTHEWORKINGTOOL
-ODEL
-INIMUM'AS 2EQUIRED'AS
PRESSURE PRESSURE
(-1 BAR BAR

PSI PSI &ILLINGTHEPISTONACCUMULATOR
(- 1 BAR BAR 3LOWLYOPENTHEPRESSURE RELIEF VALVE TO ALLOW

PSI PSI
THENITROGENTOFLOWINTOTHEPISTONACCUMULATOR
(-1 BAR BAR
4HE PRESSURE INCREASE CAN BE READ ON THE
PSI PSI PRESSUREGAUGE
#LOSETHEPRESSURE RELIEF VALVE WHEN THE
(-1 BAR BAR PRESSUREINTHEPISTONACCUMULATORHASREACHED
PSI PSI THEREQUIREDLEVEL
(-1 BAR BAR 0ULLTHEFILLINGHOSEOUTOFFILLINGVALVEw'i
PSI PSI
(-1 BAR BAR

PSI PSI
(-1 BAR BAR

PSI PSI
46 9803/1420-04 46
#HECKINGANDLOWERINGPRESSURE 5SEONLYNITROGENFROMTHEGREENGASCYLINDERTOFILL
2EMOVETHEFILLINGHOSEFROMTHEPRESSURERELIEF THEPISTONACCUMULATOR
VALVEANDCONNECTITTOTHEPRESSUREGAUGE .EVERUSEANYOTHERGASEGAIROROXYGEN
0RESSTHEFREENOZZLEOFTHEFILLINGHOSEBACKINTO $!.'%2RISKOFEXPLOSION
FILLINGVALVEw'iANDREADOFFTHEPRESSURE 7HENFILLINGTHEPISTONACCUMULATORENSURENOONE
4HEPRESSUREINTHEPISTONACCUMULATORCANBE ISINTHEVICINITYOFTHEWORKINGTOOL
LOWERED TO THE REQUIRED READING BY REPEATEDLY )FTHETOOLHASJAMMEDTHEINCREASEINPRESSUREIN
PUSHINGINANDPULLINGOUTTHEHOSENOZZLE THEPISTONACCUMULATORMAYCAUSEITTOSPRINGOUT
!FTERFILLING SUDDENLY
3CREW THE PLUG BACK ONTO FILLING VALVE w'i TO $!.'%2RISKOFINJURY
CLOSEIT
#LOSETHEVALVEONTHENITROGENCYLINDER "EFOREREMOVINGTHECOMPLETEFILLINGVALVEw'iTHE
PISTON ACCUMULATOR MUST BE COMPLETELY
/PENTHEPRESSURE RELIEFVALVEFULLYTOALLOWANY
DEPRESSURISED 4O THIS END UNSCREW THE VALVE PLUG
RESIDUALGASTOESCAPE
ANDDEPRESSTHEVALVEPISTONINTHEFILLINGVALVEUSING
2EMOVETHEPRESSURERELIEFVALVE THENOZZLEOFTHEFILLINGHOSE
#!54)/.
4HISWILLALLOWTHENITROGENTOESCAPESAFELYFROMTHE
/NLYUSETHEHOSENOZZLETORELIEVETHEPRESSURE
CYLINDERCOVEROFTHEHYDRAULICBREAKER
.EVER USE NAILS SCREWDRIVERS OR SIMILAR OBJECTS FOR
THISPURPOSEASTHEYWILLDAMAGETHEFILLINGVALVE
3UHVVXUH
3UHVVXUH
UHOLHIYDOYH
47 9803/1420-04 47
7.15 Fitting the power cell

into the hammer housing
v Stand the housing ( Fig. 49/1) upright.
v Replace any defective damping elements

(Fig. 49/2), guide plates (Fig. 49/3) (see
6).
v Fit plastic elements and fix in position using

double-sided adhesive tape; if wear is de-
tected, insert shims. (Service openings must
remain accessible).
v Lift the power cell

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

housing using a crane/hoist.
DANGER!
Never use your hands to locate or check the posi-

tion of the plastic elements or the shims when fit-
ting the power cell.
v Screw the two eye bolts (M 16) out of the cylin-

der cover.
v Fit elastic pad (Fig. 49/4).
v Using crane/hoist, place the hanger bracket on

housing and fasten using the 10 available allen
screws (Fig. 49/5), and the lock-
ing washers (Fig. 49/6) using
an allen key.
DANGER!
Only use the original allen screws to fasten the
adapter.
v The Allen screws must be tightened to the re-

quired torque. (Tightening torque, see 7.1 to
7.6).
Fig. 49
- 400 Nm for M20
- 1500 Nm for M30
- 1800 Nm for M36
48 9803/1420-04 48
&RQQHFWLQJWKH-&%$872*5($6(
7KH-&%$872*5($6( VKRXOGEHLQVWDOOHGRQWKHRXW
VLGHRIWKHKRXVLQJEHIRUHWKHEUHDNHULVILWWHGLQVLGH
WKHKRXVLQJ
*UHDVHOLQH/
&$87,21
7KHJUHDVHOLQHDQGK\GUDXOLFKRVHPXVWEHURXWHG
DVVKRZQ)LJ,WPXVWEHHQVXUHGWKDWWKH
JUHDVHOLQHDQGWKHK\GUDXOLFKRVHFDQPRYHIUHHO\
LQWKHKDPPHUER[DQGGRQRWFRPHLQWRFRQWDFW
3UHVVXUH
ZLWKWKHKRXVLQJDWDQ\SRLQW
OLQH6
1RWH
7KHSRUWVIRUWKHJUHDVHOLQHDQGWKHK\GUDXOLF
KRVHDQGWKHVFUHZFRXSOLQJRQWKHH[WHUQDOWKUHDG
IODQJH3DQGWKH-&%$872*5($6(DUH6DQG/
7KHVHWKUHDGVL]HVDUHDOPRVWLGHQWLFDODQGFDQ
OHDGWRPL[XSV
)RUWKLVUHDVRQ
1HYHUXVHIRUFHGXULQJDVVHPEO\DVWKHWKUHDGV
FRXOGEHGDPDJHG
6FUHZFRXSOLQJVZLOOOHDN
,WPXVWEHSRVVLEOHWRWLJKWHQWKHKRVHFRQQHFWLRQV
RQWKHDSSURSULDWHFRXSOLQJVE\KDQG
)LJ
49 9803/1420-04 49
)LWWLQJWKHWRRO
v )LWWKHSRZHUFHOOLQWRWKH
KRXVLQJVHH
v &OHDQDQ\GLUWIURPWKHLQVHUWLRQ]RQHRIWKH
WRRO)LJDQGJUHDVHZLWK-&%
(3+DPPHU*UHDVH
v $OVRJUHDVHWKHWZRUHWDLQHUEDUV)LJ
ZLWK-&%(3+DPPHU*UHDVH
v ,QVHUWWKHWRRO )LJ
v 7XUQWKHWRRO )LJXQWLOUHWDLQHUEDUV

)LJVOLGHLQWRREORQJKROHVLQORZHU
EUHDNHUSDUW )LJ
v 8QVFUHZ0VFUHZIURPUHWDLQHUEDU
)LJ
v ,QVHUWVHDOLQJSOXJV
)LJ
'$1*(5
5LVNRILQMXU\IURPIO\LQJPHWDOVSOLQWHUV
)LJ
v 'ULYHLQORFNLQJSLQV)LJXVLQJSLQ )LWWLQJWKHWRRO
SXQFK)LJDQGKDQGKDPPHU
)LJ
v ,QVHUWVHDOLQJSOXJV)LJDQG)LJ

LQWKHRSHQLQJVLQWKHKDPPHUKRXVLQJDIWHUILWWLQJ
DOOSDUWVDVGHVFULEHGDERYH
50 9803/1420-04 50
Large Breakers - Changing Seals
&KDQJLQJWKHVHDOV
,IOHDNDJHRFFXUVRQWKHK\GUDXOLFEUHDNHUDIWHUD
YHU\VKRUWSHULRGRIXVDJHGXHWRGLUWDFFXPXOD
WLRQVLQWKHORZHUVHDOLQJDUHDLWLVRQO\QHFHVVDU\
WRUHSODFHWKHVHDOVLQWKLVORZHUVHDOLQJDUHD,IWKH
EUHDNHULVGLVPDQWOHGDIWHUDOHQJWK\SHULRG
RIXVHDSSUR[RSHUDWLQJKRXUVLWLVDGYLV
DEOHWRUHSODFHDOOVHDOV
&KDQJLQJWKHF\OLQGHUVHDOV
v 5HPRYHWKHF\OLQGHUFRYHUVHH
v 5HPRYHWKHSLVWRQVHH

v 5HPRYHWKHF\OLQGHUVHH
5HSODFHWKHIROORZLQJVHDOVLQWKHORZHUVHDOLQJ
DUHDRIWKHF\OLQGHU
6WULSSHU )LJ
*URRYHGULQJVHDO )LJ 'HWDLO;
*URRYHGULQJVHDO )LJ
%HIRUHILWWLQJFKHFNSLVWRQDQGF\OLQGHU
ERUHIRUSRVVLEOHVFRULQJ,QWKHPDMRULW\RIFDVHV
VXFKVFRULQJFDQEHVPRRWKHGRIIXVLQJJUDLQ
HPHU\FORWK
2QFHSLVWRQDQGF\OLQGHUERUHKDYHEHHQZDVKHG
FOHDQDQGOLJKWO\FRDWHGZLWKK\GUDXOLFRLOWKHQHZ
VHDOLQJHOHPHQWVFDQEHILWWHG
8VHRQO\QHZDQGJHQXLQH-&%VSDUHSDUWV
)LJ
(QVXUHWKHVSDUHSDUWVOLVWZLWKH[SORGHGGLDJUDP &KDQJLQJWKHF\OLQGHUVHDOV
RIWKHVSDUHSDUWVIRUWKHEUHDNHULVWRKDQG
7KLVGLDJUDPVKRZVZKHUHZKLFKVHDOLQJHOHPHQW
LVILWWHGDQGLQZKLFKGLUHFWLRQ
&$87,21
:KHQILWWLQJWKHEDFNXSULQJREVHUYHSRVLWLRQRI
UDGLXV
51 9803/1420-04 51
7KHIROORZLQJGLDJUDPVLQGLFDWHKRZWKHVHDOLQJ
HOHPHQWVVKRXOGEHSUHVVHGRXWRIVKDSHIRUILWWLQJ
LQWKHDSSURSULDWHLQQHUJURRYHV
v &RDWVHDOLQJSRLQWVOLJKWO\ZLWKK\GUDXOLFRLO
v &DUHIXOO\SUHVVWKHVHDORXWRIVKDSHDVVKRZQ
LQ)LJ
&$87,21
([FHVVLYHNLQNLQJZLOOFDXVHFUDFNVDQGVXEVH
TXHQWIDLOXUH
v (QVXUHVHDOVDUHILWWHGWKHULJKWZD\URXQG
)LJ
*URRYHULQJ
v :KHQUHSODFLQJWKHJURRYHGULQJVHDOHQVXUH
WKDWWKHVHDOLQJOLSVDUHIDFLQJWKHRLOVLGH
v $IWHUVQDSSLQJLQWRWKHJURRYHFKHFNWKHILWRI
WKHVHDOYLVXDOO\DQGXVLQJ\RXUILQJHUV
v 5ROODFOHDQURXQGZRRGHQRUSODVWLFURG
DURXQGWKHFLUFXPIHUHQFHWRSUHVVWKHVHDO
EDFNLQWRVKDSHDQGHQVXUHDFRUUHFWILW
v )LWF\OLQGHUVHH&KDSWHU
v )LWSLVWRQVHH&KDSWHU
v )LWF\OLQGHUFRYHUVHH&KDSWHU
)LJ
3UHVVLQJWKHVHDORXWRIVKDSHIRUILWWLQJLQJURRYH
52 9803/1420-04 52
&KDQJLQJWKHVHDOVEHWZHHQ
F\OLQGHUDQGF\OLQGHUFRYHU
v 5HPRYHF\OLQGHUFRYHUVHH&KDSWHU
v 5HSODFHIROORZLQJVHDOV
2ULQJ )LJ
6HDOLQJULQJ )LJ
v 6HDOVDUHWREHJUHDVHG
XVLQJ-&%(3+DPPHUJUHDVHEH
IRUHILWWLQJ
v 5HILWF\OLQGHUFRYHUVHH
)LJ
6HDODUUDQJHPHQW
&KDQJLQJWKHVHDOVRQWKH
FRQWUROV\VWHP
v 5HPRYHWKHFRQWUROV\VWHPVHH
v 5HPRYHFRQWUROVOLGHYDOYHVHH
LQF\OLQGHUUHSODFHLIQHFHVVDU\
v &KDQJHVHDOLQJULQJVDQG2ULQJVDQGFRDWZLWK
-&%(3+DPPHU*UHDVH
v 5HDVVHPEOHDQGILWFRQWUROV\VWHPVHH
DQG
2EVHUYHWLJKWHQLQJWRUTXHVHH
)LJ
&KDQJLQJWKHVHDOVRQWKHFRQWUROFDVLQJFRYHU
53 9803/1420-04 53
KLJKSUHVVXUHDFFXPXODWRU
v 5HPRYHKLJKSUHVVXUHDFFXPXODWRUVHH

v &OHDQVHDWIRUKLJKSUHVVXUHDFFXPXODWRURQ
F\OLQGHU
LQF\OLQGHUFRYHUUHSODFHLIQHF
HVVDU\
v 5HSODFH2ULQJDQGEDFNXSULQJ
DQGLQVHUWZLWK-&%(3+DPPHU
*UHDVH
v 5HILWKLJKSUHVVXUHDFFXPXODWRUVHH

VHDOLQJEXVK
1RWH
v 5HPRYHWKHF\OLQGHUFRYHUVHH&KDSWHU 4XDGULQJVHDO)LJDQGRU2ULQJ)LJ
DUHQRORQJHUWLJKWLIEXEEOHVDUHREVHUYHGLQWKHRLO
v 6FUHZH\HEROWIXOO\LQWRSLVWRQ DWSRUW7DIWHUUDLVLQJWKHQLWURJHQSUHVVXUHLQWKH
DQGUDLVHE\FUDQHKRLVW SLVWRQDFFXPXODWRUWR±EDUZLWKWKHKDPPHU
O\LQJIODWDQGWKHRLOUHWXUQOLQHRSHQ
v 5DLVHSLVWRQXQWLOVHDOLQJEXVKFDQ 7KHQHZ4XDGULQJFDQEHILWWHGHLWKHUZD\URXQG
EHSXOOHGRII 7KHVOLGHULQJVHDOV)LJDUHQRORQJHUWLJKWLI
K\GUDXOLF RLO LV GHWHFWHG LQ WKH SLVWRQ DFFXPXODWRU
v 3XOOVHDOLQJEXVKIURPSLVWRQ FKDPEHU
:KHQFKDQJLQJVOLGHULQJVHDOVHQVXUHWKDWWKH
VWHSLVIDFLQJWKHRLOVLGH
5HPRYHIROORZLQJVHDOVIURPVHDOLQJIODQJH
2ULQJ )LJ
%DFNXSULQJ )LJ
2ULQJ )LJ

4XDGULQJVHDO )LJ

6OLGHULQJVHDO )LJ
2ULQJ )LJ

v /LJKWO\RLOQHZVHDOVDQGLQVHUWLQJURRYHV
v /RZHUSHUFXVVLRQSLVWRQSURYLGHVHDOLQJEXVK
ZLWKQHZVHDOVDQGILWVHH

v )LWF\OLQGHUFRYHUVHH
)LJ
&KDQJLQJWKHVHDOVLQWKHVHDOLQJEXVK
54 9803/1420-04 54
Large Breakers - Repair Work
5HSDLUZRUN
&KDQJLQJWKHH[SDQVLRQ
&KDQJLQJWKHKLJKSUHVVXUH
EROWVRQWKHKLJKSUHVVXUH
DFFXPXODWRU
DFFXPXODWRU

v &KHFNFRQGLWLRQDQGIXQFWLRQRI+HOL&RLOLQVHUWV LQF\OLQGHUFRYHUUHSODFHLIQHF
LQF\OLQGHUFRYHUUHSODFHLIQHF HVVDU\
HVVDU\
v &OHDQVHDWIRUKLJKSUHVVXUHDFFXPXODWRURQ
v &OHDQVHDWIRUKLJKSUHVVXUHDFFXPXODWRURQ F\OLQGHU
F\OLQGHUFRYHU
v 3URYLGHQHZKLJKSUHVVXUHDFFXPXODWRUZLWK
v &KHFN2ULQJDQGEDFNXSULQJUHSODFHLI QHZVHDOVVHH
QHFHVVDU\DQGLQVHUWZLWK-&%(3
+DPPHU*UHDVH v $WWDFKQHZKLJKSUHVVXUHDFFXPXODWRUVHH

v 3URYLGHKLJKSUHVVXUHDFFXPXODWRUZLWKQHZ
H[SDQVLRQEROWVDQGZDVKHUVDQGDWWDFKVHH v 2EVHUYHWLJKWHQLQJWRUTXHIRUH[SDQVLRQEROWV
VHHWR
v 7LJKWHQH[SDQVLRQEROWVLQGLDJRQDOO\RSSRVHG
SDLUV
v 2EVHUYHWLJKWHQLQJWRUTXHIRUH[SDQVLRQEROWV &$87,21
VHHWR ,IDQ\VLJQLILFDQWFKDQJHVDUHPDGHWRWKHK\
GUDXOLFV\VWHPDQHZDFFHSWDQFHLQVSHFWLRQLV
WREHFDUULHGRXWLQDFFRUGDQFHZLWKWKHUHOH
YDQWQDWLRQDOVDIHW\SURYLVLRQV
1RWH
&KHFNWKHSUHVVXUHDFFXPXODWRULQDFFRUGDQFH
ZLWKWKHQDWLRQDOVDIHW\SURYLVLRQV:HUHFRPPHQG
ILYH\HDUO\PDLQWHQDQFHLQWHUYDOV
55 9803/1420-04 55
&KDQJLQJWKHWLHURGV
1RWH
,IDGHIHFWLYHIUDFWXUHGKHDGW\SHWLHURGLVUH v ,IJDOOLQJLVGHWHFWHGLQWKHORZHUSDUWRIWKH
SODFHGLWLVQRWQHFHVVDU\WRUHSODFHWKHRWKHUWLH RWKHUWLHURGVRQWKHWKUHDGWKH\PXVWDOVREH
URGVLIWKHKDPPHUZDVQRORQJHUXVHG UHSODFHG
DIWHUWKHGHIHFWIUDFWXUHRFFXUUHG
v 3UHWLJKWHQWLHURGVLQGLDJRQDOO\RSSRVLQJ
+RZHYHULIWKHSDUWKDVEHHQGDPDJHGIRUVRPH SDLUVXVLQJWRUTXHZUHQFKWLJKWHQLQJWRUTXH
WLPHDOOKHDGW\SHWLHURGVPXVWEHUHSODFHG VHHWR
v 7KHQWLJKWHQLQGLDJRQDOO\RSSRVLQJSDLUVLQWZR
VWDJHVXVLQJDQHOHFWURQLFRUK\GUDXOLFSRZHU
ZUHQFKWXUQLQJDQJOHVVHHWR
'$1*(5
5LVNRILQMXU\WKURXJKSRZHUZUHQFKVXSSRUW v )LOOWKHSLVWRQDFFXPXODWRUVHH&KDSWHU
)LJ
5HPRYLQJ
v %HIRUHUHOHDVLQJWLHURGVEOHHGJDVIURPSLVWRQ
DFFXPXODWRUVHH
v 5HOHDVHWLHURGVXVLQJDQHOHF
WURQLFRUK\GUDXOLFSRZHUZUHQFK
v 6FUHZWLHURGVRXWRIORZHUKDPPHUSDUW
DQGSXOOXSZDUGVDQGRXW$YRLGGDPDJ
LQJWKHWLHURGV
)LWWLQJ
v 3ODFHZDVKHUVRQWKHWLHURGV
3XVKWLHURGVWKURXJKERUHVLQF\OLQGHUFRYHU
DQGF\OLQGHUDQGVFUHZ
LQWRWKUHDGHGERUHVLQORZHUSDUW
&$87,21 )LJ
v :DVKHUVDUHFRQLFDORQRQHVLGH 5HOHDVLQJWLHURGVZLWKSRZHUZUHQFK
:KHQILWWLQJZDVKHUVFRQLFDOVLGHPXVWEHIDF
LQJKHDGRIWLHURG
v %URNHQWLHURGVPXVWDOZD\VEHUHSODFHG
v $OORWKHUWLHURGVDUHWKHQUHOHDVHGDQGUH
PRYHGIRUFKHFNLQJ
56 9803/1420-04 56
5HPRYLQJVFRUHVIURP 5HPRYLQJVFRUHVRQSLVWRQ

FRQWUROVOLGHYDOYHDQGERUH DQGF\OLQGHUERUH
1RWH 1RWH
7KHFRQWUROVOLGHYDOYHPXVWEHDEOHWRPRYHHDVLO\ v 5HPRYHF\OLQGHUFRYHUVHH
LQWKHERUH,IWKLVLVQRWWKHFDVHFKHFNWRVHH
ZKHWKHUMDPPLQJLVFDXVHGE\VFRUHV v 5HPRYHSLVWRQVHH
v 5HPRYHFRQWUROVOLGHYDOYHVHH v ,IVFRUHVFDQEHVHHQRQWKHUHPRYHGSLVWRQ

DQG WKH\PXVWEHUHPRYHGE\PHFKDQL
FDOILQLVKLQJRUPDQXDOSROLVKLQJZLWKHPHU\
v 6PRRWKDZD\VFRUHVRQFRQWUROVOLGHYDOYHXV FORWK7KHSLVWRQGLDPHWHUPD\QRWEHUHGXFHG
LQJHPHU\FORWK E\PRUHWKDQPPE\PHFKDQLFDOUHZRUN
LQJ
v &KHFNERUHIRUVFRUHVLIQHFHVVDU\VPRRWKRII
XVLQJHPHU\FORWK v &KHFNF\OLQGHUERUHIRUVFRUHVSROLVKVPRRWK
LIQHFHVVDU\XVLQJHPHU\FORWK
v &DUHIXOO\FOHDQWUHDWHGVXUIDFHVWKHQRLOOLJKWO\
ZLWKK\GUDXOLFRLO
v )LWFRQWUROVOLGHYDOYHVHHDQG
&$87,21
6FRUHHQGVLQWKHJURRYHGDUHDRIWKHSLVWRQPXVW
:KHQUHVWDUWLQJWKHEUHDNHUFKHFNIRU EHFDUHIXOO\GHEXUUHG7KHVDPHDSSOLHVIRUWKH
PDOIXQFWLRQV,IWKHUHDUHVWDUWXSSUREOHPVRU VHDOLQJJURRYHVLQWKHF\OLQGHU
WKHEUHDNHUGRHVQRWUXQVPRRWKO\FRQWDFW
-&%$WWDFKPHQWV v 7KRURXJKO\FOHDQWUHDWHGSDUWVDQGDOOJURRYHV
DQGOXEULFDWHZLWKK\GUDXOLFRLO
,IVFRUHVRUJDOOLQJFDQQRWEHIXOO\UHPRYHGE\ v )LWSLVWRQVHH

FDUHIXOSROLVKLQJDGHFLVLRQPXVWEHWDNHQLQ
HDFKFDVHDVWRZKHWKHUWRILWQHZSDUWVRU
:KHQUHVWDUWLQJWKHEUHDNHUFKHFNIRU
KDYHWKHSDUWVLQTXHVWLRQUHZRUNHG
PDOIXQFWLRQV,IWKHUHDUHVWDUWXSSUREOHPVRU

WKHEUHDNHUGRHVQRWUXQVPRRWKO\FRQWDFW
-&%$WWDFKPHQWV
,IVFRUHVRUJDOOLQJFDQQRWEHIXOO\UHPRYHGE\
FDUHIXOSROLVKLQJDGHFLVLRQPXVWEHWDNHQLQ
HDFKFDVHDVWRZKHWKHUWRILWQHZSDUWVRU
KDYHWKHSDUWVLQTXHVWLRQUHZRUNHG

57 9803/1420-04 57
&KDQJLQJWKHZHDUEXVKHV
1RWH
7KLVZRUNFDQRQO\EHSHUIRUPHGLQD
ZRUNVKRSZLWKDK\GUDXOLFSUHVVRIXSWR
WRQQHVFDSDFLW\
'$1*(5
5LVNRILQMXU\E\WUDSSLQJILQJHUVHWF
v .QRFNRXWORFNLQJEROWXVLQJSLQSXQFKDQG
KDQGKDPPHU
v )LWJULSRISUHVVRXWDLGLQWRVFUHZDQG

VFUHZLQSUHVVRXWHOHPHQWERWWRPVHH
&KDSWHU
v )LWWKHSUHVVRXWDLGLQWRWKHORZHUKDPPHU )LJ
SDUWIURPEHORZUHVWRQORZHUEXVK 5HPRYLQJWKHORZHUZHDUEXVK
v 5HPRYHVFUHZDQGJULSIURPSUHVVRXW
DLGVHH&KDSWHU
v 3ODFHWKHSUHVVSXQFK)LJRQWKHSUHVV

RXWDLGIURPDERYHDQGSUHVVRXWWKHORZHU
EXVK
v )LWJULSRISUHVVRXWDLGLQWRVFUHZDQG

VFUHZLQSUHVVRXWHOHPHQWWRSVHH&KDS
WHU
v ,QVHUWSUHVVRXWDLGLQWRWKHORZHUKDPPHUSDUW
IURPEHORZUHVWRQEXIIHUULQJ
v 5HPRYHVFUHZDQGJULSIURPSUHVVRXW

DLGVHH&KDSWHU
v 3ODFHWKHSUHVVSXQFK)LJRQWKHSUHVV

RXWDLGIURPDERYHDQGSUHVVRXWXSSHUZHDU
EXVKWRJHWKHUZLWKEXIIHUULQJ )LJ
5HPRYLQJWKHXSSHUZHDUEXVKDQGEXIIHUULQJ
58 9803/1420-04 58
v )RUGLUHFWLRQRIUHPRYDOIRUEXVKHVVHH
)LJ
v %HIRUHILWWLQJEXIIHUULQJVXSHUFRROLWLQOLTXLG
QLWURJHQ1
v +HDWORZHUEUHDNHUSDUWWRDURXQG&)
v )UHH]HERWKZHDUEXVKHVIRUDERXWKRXUV
&)
SDUW
QR
PP
'$1*(5 PHDVXULQJ
SRLQW
8VHWRQJVWRKDQGOHKHDWHGFRROHGSDUWVQHYHU
XVH\RXUKDQGV
)LJ
v )LUVWILWWKHEXIIHUULQJ 'LUHFWLRQRIUHPRYDOIRUZHDUEXVKHV
v :DLWXQWLOORZHUEUHDNHUSDUWKDVFRROHGGRZQ
v 7KHQILWERWKEXVKHV
1RWH
7KHZHDUEXVKUHFHVVHVPXVWEHDOLJQHGZLWKWKH
ERUHVIRUWKHORFNLQJSLQVLQWKHORZHUKDPPHUSDUW
v )LWORFNLQJSLQDQGORFNLQJSLQEXVKHV
'$1*(5
)LJ
5HPRYLQJEXVKZLWKEXIIHUULQJ
,IQRSUHVVLVDYDLODEOHWRSUHVVRXWWKHEXVKHVWKH
5HPRYDOSODWHZHOGHGLQWREXIIHUULQJ
IROORZLQJSURFHGXUHLVSRVVLEOH
v $SSO\WKLFND[LDORUUDGLDOZHOGLQJEHDGVWRWKH
LQVLGHRIWKHZRUQZHDUEXVKXVLQJDQHOHF
WURGHZHOGHU)LJ
v 7KHVDPHSURFHGXUHFDQEHDSSOLHGIRUWKH
EXIIHUULQJ,QDGGLWLRQWRWKHLQQHUZHOGLQJLWLV
UHFRPPHQGHGWKDWDSODWHEHZHOGHGLQWRWKH
ULQJDVVKRZQLQ)LJ
v 8SRQFRROLQJWKHZHDUEXVKDQGEXIIHUULQJ
FRQWUDFWDQGORRVHQLQWKHLUVHDWV
)LJ
%XVKZLWKUDGLDOD[LDOZHOGLQJEHDGV
59 9803/1420-04 59
5HSODFLQJWKHFRPSOHWH 5HSODFLQJJXLGHSODWHVDQG

KRXVLQJ GDPSLQJHOHPHQWVLQ
KDPPHUKRXVLQJ
v 5HPRYHKDQJHUEUDFNHWVHH
v 5HPRYHWKHSRZHUFHOOIURPWKHKRXVLQJ
v 5HPRYHHODVWLFSDGVHH VHH
v 8VLQJDFUDQHKRLVWSXOOWKHSRZHUFHOO v 5HPRYHROGJXLGHSODWHVDQGGDPSLQJ
RXWRIKDPPHUKRXVLQJVHH HOHPHQWVDQGILWQHZRQHV

v 5HPRYHJXLGHHOHPHQWVDQGFKHFNIRUZHDURU
GDPDJHVHH v )LWWKHSRZHUFHOOLQWRWKHKRXVLQJ
VHH
v &OHDQVLGHIDFHVRIWKHSRZHUFHOO

v 3RVLWLRQJXLGHHOHPHQWVLQQHZKRXVLQJ
DQGIL[LQSODFHVHH
v )LWSRZHUFHOOLQWR
QHZKDPPHUKRXVLQJVHH
60 9803/1420-04 60
5HSDLULQJFUDFNHGZHOGV
,IFUDFNHGZHOGVDUHGHWHFWHGWKH\FDQEHUHSDLU
ZHOGHGDIWHUWKHEUHDNHUDQGWKHSODVWLFHOHPHQWV
KDYHEHHQUHPRYHGIURPWKHKRXVLQJ 3RLQW
6LGH SODWHWRS
$IWHUWKHQHFHVVDU\SUHSDUDWLRQVKDYHEHHQPDGH SODWHMRLQW
E\DVSHFLDOLVWUHSDLUVFDQEHFDUULHGRXW
7KHQHFHVVDU\SUHSDUDWLRQVLQFOXGH
v &OHDQLQJWKHSRLQWVLQTXHVWLRQ
v *ULQGLQJGRZQWKHFUDFNVXQWLOWKHZHOGLV 3RLQW
FUDFNIUHH 6LGHSODWHGDPSLQJ
v 3URYLGLQJVXLWDEOHZHOGILOOHUVHOHFWURGHVRU HOHPHQWEHDULQJMRLQW
ZLUHVXFKDVXVHGIRUVWHHOJUDGH6WHJ
0$*ZLUH6*6*RU(%HOHFWURGHV
v 3UHKHDWLQJWKH]RQHWREHUHSDLUZHOGHGWRDS
SUR[WR&
,ISRVVLEOHWKHUHSDLU]RQHVKRXOGEHILOOHGDQG 3RLQW
ZHOGHGIURPERWKVLGHV 6LGH SODWHERWWRP
SODWHMRLQW
)LJ
3RVVLEOHZHOGFUDFNVRQKDPPHUER[
5HSODFLQJWKHERWWRPSODWH
RQWKHKDPPHUKRXVLQJ
,IWKHERWWRPSODWHRIDKRXVLQJLVKHDYLO\
ZRUQLWFDQEHUHSODFHGVLPSO\ZLWKDQHZRQH
$IWHUUHPRYLQJWKHSLVWRQDQGYDULRXV 'LUHFWLRQRIIODPH
JXLGHHOHPHQWVIURPWKHKRXVLQJDVSHFLDOLVW FXWWLQJ
FDQUHPRYHWKHERWWRPSODWHE\IODPHFXWWLQJDQG
UHSODFHLWZLWKDQHZRQH
7KLVMREUHTXLUHVWKHIROORZLQJSUHSDUDWLRQV
v )ODPHFXWDUHDVRQWKHKRXVLQJPXVWEH
JURXQGIODW
v 3UHSDUHZHOGVHDPVVHH
v 3UHKHDWLQJWHPSHUDWXUHVHH )ODPHFXWWLQJ
v )LOOHUPDWHULDOVVHH SRVLWLRQ
v 3RVWWUHDWPHQWRIZHOGVHDPVVHH

)LJ
5HSODFLQJWKHERWWRPSODWH
61 9803/1420-04 61
5HZRUNLQJWKHUHWDLQHUSLQV :HOGVHDPSUHSDUDWLRQ
IRUWKHGDPSLQJHOHPHQWV
%HIRUHVWDUWLQJZHOGLQJZRUNUHPRYHDOOFRQWDPL
QDWLRQRQDQGDURXQGWKHVHDPHGJHV6FDOHUXVW
,ILQWKHFRXUVHRIWLPHWKHUHWDLQHUSLQVIRUWKH
RLOSDLQWDQGPRLVWXUHJLYHRIIK\GURJHQZKLFKFDQ
GDPSLQJHOHPHQWVLQWKHKRXVLQJKDYHEH
MHRSDUGLVHZHOGLQJUHVXOWVDQGUHVXOWLQFUDFNV
FRPHORRVHGXHWRWKHZLGHQLQJRIWKHERUHVWKH\
FDQEHZHOGHGEDFNLQWRSRVLWLRQ)LJ
7KHIROORZLQJVWHSVDUHQHFHVVDU\
v 5HPRYHWKHSRZHUFHOOIURPWKH 3UHKHDWLQJWHPSHUDWXUH
KDPPHUER[VHH&KDSWHU
7RDYRLGFUDFNLQJDKLJKHUZRUNLQJWHPSHUDWXUHLV
v 5HPRYHWKHWZRGDPSLQJHOHPHQWVIURPWKH UHFRPPHQGHGGHSHQGLQJRQVWHHOSODWHJUDGH
KRXVLQJDQGWKHSODVWLFSDUWVLQWKHXSSHU RYHUDOOSODWHWKLFNQHVVDQGK\GURJHQFRQWHQW
VHFWLRQRIWKHKDPPHUER[ &RPELQHGVKHHWWKLFNQHVVRI
v 5HPRYHWKHWZRUHWDLQHUSLQV PP&)

PP&)
v &RXQWHUVLQNERUHV' PPIURPDERYHz PP&)
[)LJ
v 5HLQVHUWUHWDLQHUSLQVLQERUHVDQGDOLJQWR
VL]H)LJZHOGIURPDERYHDQGFOHDQZHOG
VHDP )LOOHUV
v 2QFHWKHZHOGKDVFRROHGUHSODFHGDPSLQJ +DUGR[SODWHVVKRXOGEHZHOGHGXVLQJILOOHUVHOHF
HOHPHQWVDQGRWKHUSODVWLFSDUWV WURGHVZLUHSURGXFLQJDORZK\GURJHQFRQWHQWLQ
WKHZHOG)LOOHUDVIRU67HJ0$*ZLUH
v 5HILWWKHSRZHUFHOOLQKRXVLQJVHH 6*6*RUHOHFWURGHV(%

)LOOHUVPXVWEHVWRUHGLQVXFKDZD\DVWRDYRLG
DQ\PRLVWXUHDEVRUSWLRQ
3RVWWUHDWPHQWRIZHOGV
:HOGVPXVWEHPDGHZLWKRXWQRWFKHVRUJURXQG
IUHHRIQRWFKHVLQRUGHUWRUHGXFHWHQVLRQ
)LJ
5HZRUNLQJWKHUHWDLQHUSLQV
62 9803/1420-04 62
Large Breakers - Spares List
6SDUHV/LVW3HUFXVVLRQXQLW

#YLINDER COVER

4

#YLINDER

BREAKER

63 9803/1420-04 63
6SDUHV/LVW1RLVH'DPSLQJ

8

$ETA IL
!TTACHMENTTOANEXISTINGCARRIERREQUIRES
ANADDITIONALHANGERBRACKETMATCHING
THECARRIERINQUESTION
64 9803/1420-04 64
6SDUHOLVW-&%$872*5($6(

0ARTS ANDSECURED BY,OCTITE
)MPORTANT
4HE HOSES PARTS AND MUSTBELAIDINACCORDANCE WITHTHEDIAGRAM ENSURING THATTHEY
CAN BEMOVEDFREELY ANDDONOTMAKE CONTACTATANY POINT
65 9803/1420-04 65
66 9803/1420-04 66
Large Breakers - Appendix 1
Breaker Operating Principles

Breaker Piston
AG A1 > A 2
A1
Control Area A2
A = Ring
area Impact Area
67 9803/1420-04 67
Control Valve
Control Valve
A
1
A > A
1 2
A < A +A
1 2 ST
A
ST
A = Ring area
A
2
68 9803/1420-04 68
Stage 1 - Start Up
Stage 1 - Start Up
Ta n k
Pum p
Pi l o t l i n e
Ta n k
Up p e r o i l
cham ber Pu m p
At initial start up, oil enters the breaker and the

pressure rises. At this point the control valve is in the
upper position. As the pressure rises, the cavity at
the top of the valve also becomes pressurised
through a pilot drilling through the centre of the valve
spool (X).
69 9803/1420-04 69
Stage 2 - Return Stroke
Stage 2 - Return Stroke
Tank
Pump
Pilot line
Tank
Upper oil
chamber Pump
The hydraulic force generated by the larger surface

area at the top of the valve causes the spool to be
pushed downwards, releasing the oil from the top of
the piston and the pilot line into the tank line.
The high pressure oil acting on the lower piston now

causes the piston to rise in the cylinder.
70 9803/1420-04 70
Stage 3 - End of Return and Power Stroke
Stage 3 - End of Return and Power Stroke
Tank
Pump
Pilot line
Tank
Upper oil
chamber Pump
When the piston reaches the top of its stroke, high

pressure oil is released to the control spool via the
pilot line, raising the valve spool and allowing the
incoming high pressure oil to now act on the top
section on the piston. This prevents any further
upward movement of the piston. The larger surface
area of the top section of the piston now generates a
greater hydraulic force than the lower area and the
piston is driven downwards.
71 9803/1420-04 71
Stage 4 - Power Stroke Continued
Stage 4 - Power Stroke Continued
Tank
Pump
Pilot line
Tank
Upper oil
chamber Pump
When the piston impacts on the tool, the pilot line is

connected to tank via the control area of the piston.
This in turn allows the control valve spool to move
and exhaust the upper piston area to tank. The
pressurised oil now acting on the lower piston area
now starts to raise the piston and commences a new
cycle.
72 9803/1420-04 72
Operation of Hydraulic Brake
Tank
Pump
Pilot line
Tank
Upper oil
chamber Pump
(X)
If no ground pressure is being applied to the tool, the

piston continues its downward motion allowing high
pressure oil into the pilot line via the control area of
the piston and the lower shoulder of the piston now
enters the hydraulic brake (X). This prevents
damaging contact between the piston and the
buffer ring and also prevents further operation of the
breaker until ground pressure is re-established on
the tool and the piston is lifted out of the hydraulic
brake.
73 9803/1420-04 73
74 9803/1420-04 74
JCB Autogrease Operating Principles

Features
– Compact self-priming grease pumping unit.

– Unit mounted directly on the breaker housing.
– Greasing unit hoses protected inside the
breaker housing.
– System operated by the breaker’s internal
hydraulic system.
– No tools required to exchange the grease
cartridge ( Screw fit ).
75 9803/1420-04 75
Typical Installation
*UHDVH3XPS 3UHVVXUH+RVH
*UHDVH&DUWULGJH 'HOLYHU\+RVH
76 9803/1420-04 76
\ M
6PDOO6PDOO'HOLYHU\3LVWRQ
/RFN1XW
/DUJH'HOLYHU\3LVWRQ
6HW'HOLYHU\
&DUWULGJH6HDO
6HOI&XWWLQJ7KUHDG
&DUWULGJH3LVWRQ
*UHDVH&DUWULGJH
77 9803/1420-04 77
Lock Nut
Adjusting Screw
1 Unscrew locknut.
2 Counter clockwise: Delivery increasing.
3 Clockwise: Delivery decreasing.
4 Tighten locknut
78 9803/1420-04 78
Minimum Adjusted Pump Delivery
1 Loosen locknut.
2 Screw adjuster in fully and then unscrew by 2 turns.
3 Retighten locknut.
79 9803/1420-04 79
Maximum Adjusted Pump Delivery
1 Loosen locknut.
2 Unscrew adjuster until bottom of locknut threads are

level with pump body.
3 Tighten locknut.
80 9803/1420-04 80
Installation Schematic – Breaker not Operating
Lubrication port
Hydraulic power source
81 9803/1420-04 81
Installation Schematic – Breaker Operating
Lubrication port
Hydraulic power source
82 9803/1420-04 82
Stage 1
Stage 1
83 9803/1420-04 83
Stage 2
Stage 2
84 9803/1420-04 84
Stage 3
Stage 3
85 9803/1420-04 85
Stage 4
Stage 4
86 9803/1420-04 86
Stage 5
Stage 5
87 9803/1420-04 87
Stage 6
Stage 6
88 9803/1420-04 88
Stage 7
Stage 7
89 9803/1420-04 89
Large Breakers - Nitrogen Adaptor Reference Chart
Country Adaptor Part No Country Adaptor Part No
Algeria 40h 892/01202 Kuwait 40h 892/01202

Argentina 40b 892/01196 Kyrgyzstan 40n 892/01207
Armenia 40n 892/01207 Lebanon 40h 892/01202
Australia 40b 892/01196 Libya 40h 892/01202
Austria Direct.*** Lichtenstein Direct***
Azerbaijan 40n 892/01207 Luxembourg Direct***
Bahamas 40b 892/01196 Malawi 40b 892/01196
Bahrain 40h 892/01202 Malaysia 40l 892/01205
Bangladesh 40b 892/01196 Malta 40b 892/01196
Barbados 40b 892/01196 Mauritius 40h 892/01202
Belgium Direct*** Mexico 40h 892/01202
Bolivia 40g 892/01201 Moldova 40n 892/01207
Botswana 40b 892/01196 Morocco 40h 892/01202
Brazil 40g 892/01201 Mozambique 40h 892/01202
Bulgaria 40n 892/01207 Netherlands Direct***
Burma 40b 892/01196 New Zealand 40b 892/01196
Canada 40c 892/01197 Nigeria 40h 892/01202
Chile 40g 892/01201 Norway Direct***
China 40k 892/01204 Oman 40h 892/01202
Colombia 40g 892/01201 Pakistan 40b 892/01196
Costa Rica 40b 892/01196 Paraguay 40g 892/01201
Czech Republic Direct*** Peru 40g 892/01201
Denmark Direct*** Philippines 40b 892/01196
Djibouti 40h 892/01202 Poland Direct***
Dom. Republic 40g 892/01201 Portugal 40b 892/01196
Ecuador 40g 892/01201 Puerto Rico 40c 892/01197
Egypt 40b 892/01196 Qatar 40k 892/01204
Ethiopia 40b 892/01196 Romania 40h 892/01202
Fiji 40b 892/01196 Russ. Feder. 40n 892/01207
Finland Direct*** Saudi-Arabia 40h 892/01202
France 40h 892/01202 Singapore 40b 892/01196
Gabon 40h 892/01202 Slovakia Direct***
Gambia 40b 892/01196 Slovenia Direct***
Georgia 40n 892/01207 South Africa 40b 892/01196
Germany Direct*** Spain 40h 892/01202
Ghana 40b 892/01196 Sri Lanka 40b 892/01196
Greece 40h 892/01202 Sudan 40b 892/01196
Guatemala 40g 892/01201 Surinam 40b 892/01196
Guinea 40h 892/01202 Swaziland 40b 892/01196
Guyana 40g 892/01201 Sweden Direct***
Honduras 40g 892/01201 Switzerland Direct***
Hongkong 40b 892/01196 Syria 40h 892/01202
Hungary 40h 892/01202 Taiwan 40b 892/01196
India 40b 892/01196 Tanzania 40b 892/01196
Indonesia 40b 892/01196 Thailand 40b 892/01196
Iran 40h 892/01202 Trinidad/Tobago 40m 892/01206
Iraq 40h 892/01202 Tunisia 40h 892/01202
Ireland 40b 892/01196 Turkey 40b 892/01196
Israel 40h 892/01202 Turkmenistan 40n 892/01207
Italy 40d 892/01198 Ukraine Direct***
Ivory Coast 40h 892/01202 United Arab Emirates 40h 892/01202
Jamaica 40b 892/01196 Great Britain 40b 892/01196
Japan 40e 892/01199 Uruguay 40g 892/01201
Jordan 40h 892/01202 USA 40c 892/01197
Jugoslavia 40h 892/01202 Uzbekistan 40n 892/01207
Kazakhstan 40n 892/01207 Venezuela 40n 892/01207
Kenya 40b 892/01196 Vietnam 40b 892/01196
Korea 40f 892/01200 Zambia 40b 892/01196
Direct*** means the adaptor supplied with the Breaker is suitable for this territory.
90 9803/1420-04 90
Large Breakers - Nitrogen Adaptor Reference Chart
892/01208
892/01208
892/01205 892/01206 892/01207

892/01205 892/01206 892/01207
892/01202 892/01203 892/01204

892/01202 892/01203 892/01204
892/01199 892/01200 892/01201

892/01199 892/01200 892/01201
892/01196 892/01197 892/01198

1196 892/01197 892/01198
91 9803/1420-04 91
Large Breakers - Tool Part Numbers
Diameter Overall Length Working Length Tip Width

Breaker Type Description Part Number
mm ins. mm ins. mm ins. mm ins.
Moil Point 100 3.94 1000 39.37 560 22.05 - - 331/53613
HM860Q Flat chisel 100 3.94 1000 39.37 560 22.05 100 3.94 331/53614
Chisel wide 100 3.94 950 37.4 510 20.08 200 7.87 331/53618
Moil Point 115 4.53 1120 44.09 685 26.97 - - 331/53895
HM1260Q Flat chisel 115 4.53 1120 44.09 685 26.97 115 4.53 331/53896
Blunt tool 115 4.53 1120 44.09 685 26.97 - - 331/53897
Moil Point 135 5.31 1140 44.88 625 24.61 - - 331/54339
HM1560Q Flat chisel 135 5.31 1140 44.88 625 24.61 - - 331/54340
Blunt tool 135 5.31 1140 44.88 625 24.61 - - 331/54341
Moil Point 140 5.51 1200 47.24 650 25.59 - - 331/54343
HM1760Q Flat Chisel 140 5.51 1200 47.24 650 25.59 140 5.51 331/54344
Blunt tool 140 5.51 1200 47.24 650 25.59 - - 331/54345
Moil Point 150 5.91 1150 45.28 500 19.69 - - 331/54347
HM2460Q Flat chisel 150 5.91 1150 45.28 500 19.69 150 5.91 331/54348
Blunt tool 150 5.91 1150 45.28 500 19.69 - - 331/54349
Moil Point 165 6.5 1300 51.18 595 23.43 - - 331/54350
HM3060Q Flat chisel 165 6.5 1300 51.18 595 23.43 165 6.5 331/54351
Blunt tool 165 6.5 1300 51.18 595 23.43 - - 331/54352
Moil Point 180 7.09 1400 55.12 620 24.41 - - 331/54354
HM4160Q Flat chisel 180 7.09 1400 55.12 620 24.41 180 7.09 331/54355
Blunt tool 180 7.09 1400 55.12 620 24.41 - - 331/54356
Note: A standard Chisel or Asphalt Cutter is supplied with the cutting face perpendicular to the boom.
A Parallel Chisel or Asphalt cutter have the cutting face parallel with the boom.
A range of steels are available to meet all applications.
Manufactured from high quality materials for long life.
Use tool selection guide below.
MOIL - Universal - For layered rock and reinforced concrete, where twisting could occur.
PYRAMID POINT (All Moils above 100mm diameter)-.
CHISEL - Standard tool for penetrative work. e.g. Mining, foundations, trenching, demolition.
BLUNT - For impact breaking. e.g. Mining, breaking oversizes, demolition.
92 9803/1420-04 92
Large Breakers - Breaker Part Number Matrix
Part No. Machine DESCRIPTION

980/90213 JS130,JZ140 HM860 with Moil
980/90289 JS130,JZ140 HM860 with Chisel
980/90215 JS130,JZ140 HM1260 with Moil
980/90290 JS130,JZ140 HM1260 with Chisel
980/90216 JS160,JS180 HM1260 with Moil
980/90291 JS160,JS180 HM1260 with Chisel
980/90247 JS160,JS180 HM1560 with Moil
980/90218 JS200,JS220 HM1560 with Moil
980/90219 JS200,JS220 HM1760 with Moil
980/90220 JS240,JS260 HM1760 with Moil
980/90221 JS240,JS260 HM2460 with Moil
980/90222 JS330 HM2460 with Moil
980/90297 JS330 HM2460 with Chisel
980/90223 JS330 HM3060 with Moil
980/90224 JS460 HM3060 with Moil
980/90225 JS460 HM4160 with Moil
980/90264 HM860Universal with Moil
980/90265 HM860Universal with Chisel
Universal Options
93 9803/1420-04 93

Service Manual: HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 Onwards

Uploaded by

Copyright:

Available Formats

Service Manual: HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 Onwards

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: HM Range Medium and Large Hydraulic Breakers, Serial Nos. 1095001 Onwards

Uploaded by

Copyright:

Available Formats

HM Medium Breakers 1

Section 1 - Medium Breakers

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

Medium Breakers - HM386Q

Safety Any unauthorised use or copying of the contents of this

Using this Manual

Important positional Direction Inspect and replace New parts

To be avoided Okay Force Turning to end position

Oil Loctite 243 Gas release Scrap

Contact sound Minutes Grease Frozen

Torque On the excavator Cracks In turn

Use this as a checklist before working on the breakers.

Torque wrench 0 - 650 Nm

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

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

Item Part No. Description HM165Q HM265Q HM365Q HM495Q

Item Part No. Description HM165Q HM265Q HM365Q HM495Q

998/11253 Mandrel Assembly of bushing z

TBA Assembly tool Helicoil thread inserts

998/11249 Removal tool Removal of tool bushing z

Item Part No. Description HM165Q HM265Q HM365Q HM495Q

998/11242 Drift Rear wiper seal z

Item Part No. Description

998/11322 Gas regulator Charging of high pressure and low

Field Bushing Exchange

Charging the Accumulator

If the breaker hanger bracket is changed, ensure it has the

Table 1. Tightening Torque

(1) For bolts used with nord-lock washers and thread

Stage 1 - Start Up Stage 2 - Return Stroke

Stage 3 - Power Stroke Stage 4 - End of Power Stroke

The following tools are special tools required for

ST2 M10 x 130 full threaded

For removal of back head

At the same time the lower end of the piston gets

The hydraulic oil at the upper end of the piston becomes

Model HM165Q HM265Q HM385Q HM386Q HM495Q

Nitrogen Adaptor Reference Chart

Country Adaptor Part No. Alternative Part No.

Country Adaptor Part No. Alternative Part No.

Country Adaptor Part No. Alternative Part No.

Country Adaptor Part No. Alternative Part No.

892/01205 892/01206 892/01207

892/01202 892/01203 892/01204

892/01199 892/01200 892/01201

892/01196 892/01197 892/01198

Tool Part Numbers

Model Description Diameter Overall Working Tip Width Part No.

Breaker Part Number Matrix

Model Machine Part No.

HM Range Medium and Large Hydraulic

Section 2 Large Breakers

Chapter Title Page

Chapter Title Page

Chapter Title Page

Nitrogen Adaptor Reference Chart

Tool Part Numbers

Breaker Part Number Matrix

iii 9803/1420-04 iii

'HVLJQDWLRQ 4W\ -&%3DUW1RV

&KDUJLQJGHYLFH

3RZHUZUHQFK +HOL&RLOWRROV

'HVLJQDWLRQ -&%3DUW1R ,WHP 'HVLJQDWLRQ 8VH

,WHP 'HVLJQDWLRQ -&%3DUW1R

+LJK 7RRO -&%(3+DPPHU*UHDVH