CONTENTS

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

!
WARNING
Study this service manual before attempting to maintain the
breaker. You must understand and follow the instructions in this
service manual. If you are unsure of anything ask your JCB dealer
or employer. Do not guess, or you or others could be killed or
seriously injured.

9803/1250 Issue 3
A1 INTRODUCTION A1
ABOUT THIS MANUAL

To ensure that the JCB series of hydraulic breakers BREAKER MODEL AND SERIAL NUMBER
can be operated efficiently and safely, they must be
serviced and maintained regularly. This manual is The following breakers are covered by this manual:
designed to give you a good understanding of the
breaker and provide detailed maintenance information. 1 Standard handle breakers
2 Vibro-damped handle breakers
It is assumed that personnel carrying out maintenance 3 ‘D’ handle picks
have at least a sound knowledge of workshop 4 ‘T’ handle picks
practice, safety procedures and general techniques 5 HM 22
associated with the repair of hydraulic equipment. 6 HM 25
Details of such are, therefore, generally omitted from 7 HM 29
the manual, the intention being to convey only the 8 HM 26 (Non EU)
more specialised information concerning particular
aspects of the breaker or component in question. The serial number of your breaker is stamped on the
breaker as shown. It is important to quote the serial
For example, renewal of oil seals, gaskets etc. and any number when making repairs or ordering parts.
component showing obvious signs of wear or damage Identification of the serial number is the only means of
is expected as a matter of course and information on ensuring that you receive the correct part for your
these matters, therefore, only included where a particular breaker.
specialised procedure or range of wear tolerances is
required. Similarly, it is expected that components be
thoroughly cleaned and lubricated, where appropriate,
also that any opened hose connections will be blanked
to prevent entry of dirt and excessive loss of hydraulic
fluid.

For specific details regarding choice of breaker,

operation and choosing steels etc., reference should
be made to the Operator’s Handbook which was
supplied with the breaker.

USING THIS MANUAL

Read this manual from front to back before attempting

to maintain the breaker for the first time. Particular
attention must be given to all the safety aspects which
are provided. General safety warnings are given in this
chapter and specific safety warnings are given
throughout the book. Read all the safety warnings
regularly so you do not forget them.

UNITS OF MEASUREMENT

The S.I. system is used throughout. For example,

liquid capacities are given in litres. The Imperial units
are given in parentheses ( ) e.g. 28 litres (6 U.K.gal).

EHTMA CATEGORIZATION

c
20LPM AT 138 BAR
D
30LPM AT 138 BAR
The JCB series of hydraulic breakers are categorized
ETHMA CATEGORY ETHMA CATEGORY by the EHTMA as Category ‘C’ or ‘D’ breakers and can
TO AVOID RISK OF INJURY
be safely used on any hydraulic powerpack displaying
TO AVOID RISK OF INJURY
CONNECT ONLY TO CATEGORY CONNECT ONLY TO CATEGORY the green EHTMA ‘C’ or ‘D’ decals as shown below.
"C" POWERPACKS "D" POWERPACKS

9803/1250 Issue 2
A2 INTRODUCTION A2
TORQUE SETTINGS

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

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

TABLE OF IMPORTANT TIGHTENING TORQUES

Tightening Points Tightening Torques Capscrew

Nm kgf m lbf ft Size

Top cover to head capscrews (Standard, 20 kg & 23 kg) 135 13.8 100 M12
Top cover to head capscrews (Standard, 26 kg) 215 21.9 158 M14

Handle bracket to head capscrews (Vibro, 22 kg & 25 kg) 135 13.8 100 M12
Handle bracket to head capscrews (HM22 & HM25) 135 13.8 100 M12
Handle bracket to head capscrews (Vibro, 28 kg) 215 21.9 158 M14
Handle bracket to head capscrews (HM29) 215 21.9 158 M14

Handle to top cover capscrews (Standard, 20kg, 23kg & 26 kg) 67 6.8 50

Top cover to Handle bracket capscrews (Vibro, 22kg, 25kg & 28 kg) 16 1.6 11.9
Top cover to Handle bracket capscrews (HM22,HM25,HM29) 16 1.6 11.9

Barrel to nose capscrews (Standard 20, 23 kg & Vibro 22, 25kg) 135 13.8 100 M12
Barrel to nose capscrews (HM22 & HM25) 135 13.8 100 M12
Barrel to nose capscrews (Standard 26 kg & Vibro 28 kg) 215 21.9 158 M14
Barrel to nose capscrews (HM29) 215 21.9 158 M14

Head assy to barrel/nose assy (Standard 20 kg & Vibro 22 kg) 135 13.8 100 M12
Head assy to barrel/nose assy (HM22) 135 13.8 100 M12
Head assy to barrel/nose assy (Standard 26 kg & Vibro 28 kg) 215 21.9 158 M14
Head assy to barrel/nose assy (HM29) 215 21.9 158 M14

Accumulator top to head capscrews (‘D’ & ‘T’) 80 8.1 59 M10

Barrel to head capscrews (‘D’ & ‘T’) 135 13.8 100 M12

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

9803/1250 Issue 2
A3 INTRODUCTION A3
SAFETY DECALS

Decals on the breaker warn you of particular

hazards.Read, and make sure you understand the
safety message before you work with the breaker.

Keep all decals clean and readable. Replace lost or

damaged decals. The decals and their attachment
points on the breaker are as shown. Each decal has a
part number printed on it. Use this number to order a
new decal from your JCB Distributor, specifying the
language required.

In addition to the decals shown in the illustration

below, possibly three (3) other decals may be fitted.
These are year/model number, tool size and model
type. They have been omitted from the illustration for
clarity.

The model shown is an HM 25 but all other models are

similar.

50

9803/1250 Issue 1
A4 INTRODUCTION
SAFETY FIRST - YOURS AND OTHER PEOPLE’S
All hydraulic equipment can be hazardous. When hydraulic
equipment is correctly operated and properly maintained,
they are safe machines to work with. But when correct
operation and maintenance routines are not followed, the
machines can be a danger to you (the operator) and others.
In this handbook and on the machine you will find warning
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not
understand the warning messages, ask your employer or
JCB Dealer to explain them.
SAFETY CHECK LIST
GENERAL SAFETY
! WARNING
Handbook
You and others can be injured if you operate or maintain the
machine without first studying this handbook. Read the
instructions before operating the machine. If there is
anything that you do not understand, ask your employer or
JCB Dealer to explain it. Keep this handbook clean and in
good condition. Do not operate the machine without a
handbook readily available or if there is anything on the
machine that you do not understand.
! WARNING
Decals
You can be injured if you do not obey the decal safety
instructions. Keep decals clean. Renew unreadable and
missing decals before operating the machine. Make sure
replacement parts include warning decals where necessary.
OPERATING SAFETY
! WARNING
Machine Condition
A defective machine can injure you or others. Do not operate
a machine which is defective or has missing parts. Make
sure the maintenance procedures in this handbook are
complete before using the machine.
! WARNING
Hydraulic Tools
Hydraulic tools can be dangerous. Observe all safety
instructions relevant to the tool you will be operating. If in
any doubt, consult you JCB Dealer.
9803/1250
A4
But safety is not just a matter of responding to the warnings.
All the time you are working on or with the machine you
must be thinking what hazards there might be and how to
avoid them.
Do not work with the machines until you are sure that you
can control them.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember BE CAREFUL
BE ALERT
BE SAFE
! WARNING
Clothing
You can be injured if you do not wear correct clothing. Loose
clothing can get caught in the machinery. Wear protective
clothing to suit the job. Examples of protective clothing are:
hard hat, safety shoes, safety glasses, a well fitting overall,
ear protectors and industrial gloves. Keep cuffs fastened. Do
not wear a necktie or scarf. Keep long hair restrained.
! WARNING
Care and alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
! WARNING
Regulations
Obey all laws, worksite and local regulations which affect
you and your machine.
! WARNING
Practice
You or others can be killed or seriously injured if you do
unfamiliar operations without first practicing them. Practice
away from the worksite on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
! WARNING
Exhaust Gasses
Breathing the machine exhaust gases can harm and possibly
kill you. Do not operate in closed spaces without making
sure there is good ventilation.
Issue 1
A5 INTRODUCTION
SAFETY CHECK LIST (continued)
! WARNING
Communications
Bad communications can cause accidents. Keep people
around informed of what you will be doing. If you will be
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
! WARNING
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in a
closed area where there is flammable material, vapour or
dust.
! WARNING
Hot Surfaces
Under normal working conditions the engine components,
particularly the exhaust system, will get hot - DO NOT
TOUCH.
The hydraulic oil, pump, valve and tank can also reach
temperatures high enough to burn - DO NOT TOUCH.
! WARNING
Noise
Excessive noise can be hazardous to your health. Always
wear ear defenders when operating the machine.
MAINTENANCE SAFETY
! WARNING
Repairs
Do not try to do repairs or any type of maintenance work
which you do not fully understand, get the work done by a
specialist engineer.
! WARNING
Modifications
Non-approved modifications can cause injury and damage.
Contract your JCB Dealer before modifying the machine.
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
9803/1250
A5
! WARNING
Petrol
Petrol is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not follow
these precautions.
! WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
! WARNING
Fires
Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use carbon
dioide, dry chemical or foam extinguishers. Contact your
nearest Fire Department as quickly as possible. Firefighters
should use self-contained breathing apparatus.
! WARNING
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers.
Issue 1
B MAINTENANCE B
CONTENTS

Lubricants - Health and Safety B1

Hygiene
Storage
Handling
First aid - Oil
Fires
Waste disposal

Service Schedules B2
Daily
Monthly

Breaker dismantling - HM22, 25, 29 B3

Breaker inspection - HM22, 25, 29 B6

Breaker assembly - HM22, 25, 29 B8

Charging the accumulator B11

Equipment required
Charging pressure
Charging procedure

Fault Finding B12

Specifications - HM22, 25, 29 B12

Exploded View - HM26 (Non EU) B13

Servicing - HM26 (Non EU) B14

Exploded View - HM22, 25, 29 B15

NOTE: SEE SECTION C FOR MAINTENANCE OF BREAKERS

OTHER THAN HM22, 25 OR 29.

9803/1250 Issue 1
B1 MAINTENANCE
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand this
information and the publications referred to. Make sure
that all of your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purpose.
However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take
special care when handling used oils which may be
diluted with fuel contamination.
Whenever you are handling oil products you should
maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued by
your Local Health Authority, plus the following.
Storage
Always keep lubricants out of reach of children. Never
store lubricants in open or unlabelled containers.
Handling
New Oil
There are no special precautions needed for the
handling or use of new oil, beside the normal care and
hygiene practices.
Used Oil
Used oils contain harmful contaminants. Here are pre
cautions to protect your health when handling used oil.
1 Avoid prolonged, excessive or repeated skin
contact with used oil.
2 Apply a barrier cream to the skin before handling
used oil.
3 Note the following removing oil from the skin:
a Wash your hands thoroughly with soap and
water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel or paraffin for
washing.
9803/1250
B1
e Avoid skin contact with oil soaked clothing.
f Do not keep oily rags in pockets.
g Wash dirty clothing before reuse.
h Throw away oil soaked shoes.
First Aid-Oil
Swallowing
If oil is swallowed do not induce vomiting. Get medical
advice.
Eyes
In the case of eye contact, flush with water for 15
minutes. If irritation persists get medical attention.
Skin
In the case of excessive skin contact, wash with soap
and water.
Spillage
Absorb on sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Fires
Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self -contained breathing
apparatus.
Waste Disposal
All waste products should be disposed of in
accordance with the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour
used oil into sewers, drains or on the ground.
Issue 1
B2 MAINTENANCE B2
SERVICE SCHEDULES

! WARNING To make sure your breaker keeps working to maximum

Maintenance work must only be done by efficiency, it is essential that it is properly and regularly
competent personnel. maintained in accordance with the service schedules
A-3-1-1 included in this manual.

! CAUTION Badly maintained equipment can be a danger to the

operator and the people working around him. Make
Only use lubricants and hydraulic fluids sure that the regular maintenance and lubrication jobs
recommended by JCB Attachments. listed in the service schedules are done to keep the
equipment in a safe and efficient working condition.

Any defects found during the regular routine

maintenance checks must be rectified before the
equipment is used.

Daily Monthly
Clean Check (Breaker disconnected)

1 The breaker, its steels and its hoses. 1 Torque tightness of all fasteners.

Check (Breaker disconnected) 2 The hexagon bush in the nose casting for wear or
damage.
2 All hydraulic connections.
3 The cutting steel shanks for excessive wear.
3 For damage to the breaker, its steels and its
hoses. Lubricate

1 Vibro-damped handle types only. Spray the

trigger and all contacting parts with suitable
lubricant.

Every 600 Operating Hours or Yearly

(which ever occurs first.)

1 Overhaul the breaker.

9803/1250 Issue 1
B3 MAINTENANCE B3
BREAKER DISMANTLING - HM 22, 25, 29

A
S

1 Using a press, remove roll pins Q from the 4 Prepare for oil spillage and remove the two upper
nose.This releases latch R, latch plunger S and barrel fixing capscrews. Remove the barrel A.
the plunger spring.

C
D

2 Unless signs of damage or wear are evident it is 5 Push the piston C and piston feeder D out of the
not necessary to remove the tool bush. Removal barrel. Remove 3 ‘O’ rings from the barrel.
will be dealt with in the following ‘Breaker
Inspection’.

F
B E

3 Before commencing dismantling, clean 6 Unscrew and remove check valve E ensuring that
externally. Remove the hoses. Remove the two the breaker is positioned as shown above so as
lower barrel fixing capscrews. Separate the to avoid losing the check valve ball F.
barrel A from the nose B.

9803/1250 Issue 1
B4 MAINTENANCE B4
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)

7 Remove the seals from the lower section of the 10 Remove screws (4 off each cover) from covers N
barrel casting. A slide hammer will be necessary (2 off), this will expose the handle mechanism.
to remove the seal housing.

Z
J

H
G Z

8 Remove the housing cap G and the spool H from 11 Unscrew the handle pivot pin Z nearest the
the head J. trigger pin. Withdraw handles assemblies from
the handles control bracket.

M
L

K G

9 Remove the plug K, seal washer L, spring and 12 Remove vibration dampening springs.
trigger spool M from the head J. Examine seals
on the head J and housing cap G.

9803/1250 Issue 1
B5 MAINTENANCE B5
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)

T
P

13 Remove the cover screw T to expose the 16 Remove the four top cover retaining screws P
charging screw. and remove the cover.

Note: There are two long and two shorter retaining

screws

T Y
W

14 Loosen the charging screw U slowly 17 Remove the trigger pin W and the ‘O’ ring seal Y
approximately 3 or 4 turns, listening for all the from the head.
gas to escape. Refit the cover screw T.

15 When you are sure that all the gas in the 18 Remove the diaphragm X from the head.
accumulator has been evacuated, remove the
safety screw V from the head.

9803/1250 Issue 1
B6 MAINTENANCE B6
BREAKER INSPECTION - HM 22, 25, 29

D
C
A

1 Examine the piston C, piston feeder D and barrel 4 Examine the seals for signs of wear. Pay
A for signs of damage. Small scratches can be particular attention to their lips. Obtain new seals
carefully removed with fine emery cloth. if necessary or if the piston is changed.

J
D
C
A
H

G
2 Deep grooves or signs of pick-up (especially on 5 Examine the housing cap G and spool H for
the lower sealing portion of the piston) will require signs of damage. Obtain new components if
replacement of the component. Examine seal on necessary.
feeder D, replace if necessary.

F M
L

3 Examine the check valve ball F and ball seats for 6 Examine the plug K, seal washer L, spring and
signs of damage or excessive wear. Obtain new trigger spool M for signs of damage or wear.
components if necessary. Obtain new components if necessary.

9803/1250 Issue 1
B7 MAINTENANCE B7
BREAKER INSPECTION - HM 22, 25, 29 (cont’d)

nn
jj
ii
ff

S
aa
R

7 Examine the roll pins Q, latch R, latch plunger S 10 Check the spring ring aa, guide rings ff (2 off),
and plunger spring for signs of damage or wear. carrier ii, spring jj and tool bush nn for damage
Obtain new components if necessary. and wear. Replace as necessary.See Note:below

cc

aa

8 Should it be necessary to remove the 11 Examine the diaphragm X for signs of damage.
components of the tool bushing, firstly push in Pay particular attention for signs of cracking
the spring ring aa with a sharp instrument via the around the diaphragm insert. Replace as
hole shown at cc. necessary.

Note: A hydraulic press will be required to remove to

remove the steel tool bush nn. See item 10.

ee

aa

9 Grip the spring ring aa with a suitable pair of

pincers ee and remove. The sliding bush and
other components can now be removed from the
nose (see item 10).

9803/1250 Issue 1
B8 MAINTENANCE B8
BREAKER ASSEMBLY - HM 22, 25, 29

! CAUTION
Before commencing assembly, all components
O
must be scrupulously cleaned.
A-3-1-4

Note: During assembly, apply Multi Gasket Loctite 3 Fit the trigger pin O into the handle bracket. Fit
518 (JCB Part No. 4102/1212) to all joint faces. Use the handle bracket to the head. Treat the threads
new seals and ‘O’ rings throughout. of the safety screw V with Loctite 270 and fit to
the head.

1 Place diaphragm X into the head, ensuring that 4 Fit the handle assembly springs. Coat the
the diaphragm insert is uppermost (as shown contacting surface of the handle furthest from
above). Fit new ‘O’ ring seal Y. the trigger pin (see item 5) and fit to the handle
bracket.

M
L

2 Fit the trigger spool M, spring, seal washer L and 5 The illustration above shows the trigger handle
plug K into the head J. Fit seal on head unit J. after coating with a suitable lubricant before
fitting.

9803/1250 Issue 1
B9 MAINTENANCE B9
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)

A
ss

tt

Z zz

6 Treat the thread of the pivot pin Z with Loctite 9 Assemble the seals into the lower section of the
270 and fit the pin where indicated. barrel casting A. Ensure seal ss has the open
face uppermost,seal zz is fitted in the same
direction.

E
E
F

7 Check that all parts of the trigger and other parts 10 Treat the threads E of the check valve with
in contact are well coated with lubricant. (see Loctite 542. Ensure that the ball F is clean and
item 5) undamaged. Obtain a new seal. Assemble the
check valve.

A
J

H F
E
G

8 Fit the housing spool H and the housing seal G 11 Fit the check valve into the barrel A. Always
into the head J. Fit a new ‘O’ ring to the housing ensure that ball F has been fitted.
seal G.

9803/1250 Issue 1
B10 MAINTENANCE B10
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)

12 Bolt the barrel A to the nose B. Torque tighten 15 Replace covers N (2 off).
the capscrews progressively using a Gedore
narrow head torque wrench (part no. 7200-01).
See Torque Figures on Page A2

C
D

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

and piston feeder D into the barrel A.

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

9803/1250 Issue 1
B11 MAINTENANCE
CHARGING THE ACCUMULATOR - HM 22, 25, 29
! WARNING
Use only nitrogen gas to charge the accumulators. The
use of any other gas can cause the accumulators to
explode. Remember that although nitrogen is not
poisonous, you can be killed by suffocation if it displaces
air in your workplace. Do not allow excessive quantities
of nitrogen to be discharged into the atmosphere.
This procedure must not be carried out with the breaker
(or pick) connected to a source of hydraulic supply.
During charging, the breaker must be securely mounted
in the upright position. This prevents the breaker falling
over whilst charging, thereby preventing uncontrolled
escape of gas.
EQUIPMENT REQUIRED.
a Nitrogen bottle
Minimum residual pressure 70 bar (1000lbf/in2 )
b Regulator (with contents and outlet gauge)
Outlet pressure should be controllable up to 55 bar
(800 lbf/in2 )
c Charging adaptor (JCB part no. 929/05800)
together with 3/8 in. BSP Dowty washer.
d Connecting hose
Suitable hose of minimum operating pressure 207 bar
(3000 lbf/in2), together with female coupling (JCB part
no.929/06303).
CHARGING PRESSURE
The charging pressure should not exceed 50 bar (800
lbf/in2). Refer to Specification section for specific
accumulator pressures.
4
9803/1250
B11
CHARGING PROCEDURE
1 Remove the slotted cover screw 1 from the breaker.
2 Using a 4 mm. Allen key 2, slowly loosen the charging
screw approximately 3 turns. Do not remove the screw.
3 Fit the 3/8 in. Dowty washer 5 to the charging adaptor 3
and screw into the breaker. Do not overtighten, hand
tight is adequate.
4 Ensure that the nitrogen bottle outlet pressure is at zero
and then connect the charging hose 4 to the charging
adaptor 3.
5 Gradually increase the nitrogen bottle outlet pressure
until the required level is reached (see Specification
section).
6 Push in knob 6 on the charging adaptor 3 to engage the
charging screw and tighten. Do not overtighten.
7 Shut the regulator valve on the nitrogen bottle and using
the venting screw 7, release the trapped gas in the
hose.
8 Disconnect the charging hose 4 and unscrew the
charging adaptor 3 from the body of the breaker.
9 Finally, tighten the charging screw using a 4mm. Allen
key 2 and refit the cover screw 1 after applying Loctite
270 to the threads.
5
6 1
X3
3 7
2 743310
Issue 1
B12 MAINTENANCE B12
OPERATOR FAULT FINDING

*The remedy in certain cases should be carried out by your JCB dealer

Symptom Possible Fault Remedy

Breaker fails to operate. No flow from supply. *Check output with flow and pressure tester.

Hoses incorrectly fitted. Check that pressure feed is connected to

top port on the breaker.

Insufficient movement of *The trigger spool should move approx.

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

Main spool jammed or *Remove and check.

damaged. Clean all associated parts.

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

Breaker lacks breaking power. Insufficient available *Check Main Relief Valve -
pressure. minimum setting 76 bar (1100 lbf/in2) for the 22 kg
Breaker and 110 bar (1595 lbf/in2) for the 25 and
29 kg Breaker.

Low accumulator gas pressure *Re-charge the accumulator

(Normally associated with
violent shaking of hoses).

Hexagon bush in nose Apply JCB Retainer( High Strength ) and press back.
casting loose.

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

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

(6.16 - 7.04 gal/min).

Cold oil. Warm up the oil supply. Optimum

temperature 20 - 70C (68 - 158F).

High return line back pressure. *Check return line back-pressure.

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

Incorrect oil. Use only JCB Hydraulic Oil HP32

(part no. 4002/1000).

Breaker runs hot. Inadequate cooling of Check oil supply has adequate cooling.
hydraulic oil. Temperature should not exceed
80C (176F).

Specifications
Min. Acc.
EHTMA Pressure Relief Valve Gas
Model Length Weight Steel Size mm (in) Noise Level Vibration Category Flow Rate Range Settings Pressure
929/92400 760 mm 25 kg 32 x 160 (11/4 x 61/4) 109 Lwa 4.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 43 bar
929/92500 720 mm 22 kg 22 x 82.5 (7/8 x 31/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92600 680 mm 22 kg 25 x 108 (1 x 41/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92700 730 mm 29 kg 32 x 160 (11/4 x 61/4) 108 Lwa 5.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 50 bar
929/92900 730 mm 29 kg 32 x 160 (11/4 x 61/4) 110 Lwa 5.9 m/s 2 D 28-32 L/Min 90-110 bar 110 bar 50 bar

Noise Level Standard:

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

9803/1250 Issue 1
B13 MAINTENANCE B13
BREAKER HM26 (NON EU)

9803/1250 Issue 1
B14 MAINTENANCE B14
BREAKER HM26 (NON EU)

HM26 (NON EU) - Servicing

It should be noted that, when servicing this breaker

(shown on page B12), detail for the handle only
reference should be made to Section C - Standard
handle breakers(from 9803/1250 Issue 1).

The remainder of the breaker , head, barrel and nose

sections, are covered in Section B - respective
sections.

9803/1250 Issue 1
B15 MAINTENANCE B15
BREAKER - HM22, 25, 29

9803/1250 Issue 1
C MAINTENANCE C
CONTENTS

Breaker dismantling - Standard and Vibro-damped C1

Breaker inspection - Standard and Vibro-damped C5

Breaker assembly - Standard and Vibro-damped C7

Breaker dismantling - ‘D’ and ‘T’ picks C8

Breaker inspection - ‘D’ and ‘T’ picks C14

Breaker - ‘D’ and ‘T’ picks C16

Charging the accumulator C19

Equipment required
Charging pressure
Charging procedure

Fault Finding C20

9803/1250 Issue 1
C1 MAINTENANCE C1
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED

! WARNING ! WARNING
Accumulator The breaker must be disconnected from its source
The breaker incorporates a pressure accumulator. of hydraulic power before any maintenance is
This accumulator is pressurised even when there is carried out.
no hydraulic pressure to the breaker. Attempting to
dismantle the accumulator without first releasing
the pressure can cause injury or death. This
procedure must be carried out by a qualified
person.

Note: Unless otherwise indicated, the following 1 Before commencing dismantling, thoroughly
instructions apply to both the standard handle and clean all external parts.
vibro-handle type breakers.

2 Remove the hoses. Remove the two lower barrel 3 The lower portion of the piston C and the seal
fixing capscrews. Separate the barrel A from the housing and seal will be exposed.
nose B.

4 Prepare for oil spillage and then remove the two 5 Push the piston C and piston feeder D out of the
upper barrel fixing capscrews. remove the barrel barrel.
A.

9803/1250 Issue 1
C2 MAINTENANCE C2
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

6 Unscrew and remove check valve E ensuring that 7 Remove the seals from the lower section of the
the breaker is positioned as shown above so as to barrel casting. A slide hammer will be necessary
avoid losing the check valve ball F. to remove the seal housing.

8 Remove the housing cap G and the spool H from 9 Remove the plug K, seal washer L, spring and
the head J. trigger spool M from the head.

10 For standard handle breakers only, Using a 11 For standard handle breakers only, remove the
press, remove roll pins N from the top cover and capscrew from inside each handle and remove
remove the trigger. Withdraw the trigger pin O. the handles from the top cover.

9803/1250 Issue 1
C3 MAINTENANCE C3
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

12 For vibro-damped handle breakers only, remove 13 For vibro-damped handle breakers only,
the four top cover retaining screws P and remove unscrew the handle pivot pin Z nearest the trigger
the cover. pin. Withdraw the handle assembly from the
control handles bracket.

14 For vibro-damped handle breakers only, 15 For vibro-damped handle breakers only, using
withdraw the remaining handle assembly a press, remove roll pins Q from the nose. This
complete with handle pivot. Remove the springs. releases latch R, latch plunger S and the plunger
spring.

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

Note: Once gas has been released, a special charging

tool (part no. 929/05800) is required to re-charge the
accumulator. Re-charging the accumulator must only
be undertaken by a suitably qualified person.

16 Remove the cover screw T to expose the

charging screw.

9803/1250 Issue 1
C4 MAINTENANCE C4
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)

17 Loosen the charging screw U slowly 18 For standard handle breakers only, when you
approximately 3 or 4 turns, listening for all the gas are sure that all the gas in the accumulator has
to escape. Refit the cover screw T. been evacuated, remove the safety screw V from
the head.

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

21 For vibro-damped handle breakers only, 22 Remove the diaphragm X and ‘O’ ring seal Y from
withdraw the trigger pin O. Remove the four the head.
capscrews and remove the handle bracket from
the head.

9803/1250 Issue 1
C5 MAINTENANCE C5
BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED

1 Examine the piston C, piston feeder D and barrel 2 Examine the check valve ball F and ball seats for
A for signs of damage. Small scratches can be signs of damage or excessive wear. Obtain new
carefully removed with fine emery cloth. Deep components if necessary.
grooves or signs of pick-up (especially on the
lower sealing portion of the piston) will require the
replacement of the component.

3 Examine the seals for signs of wear. Pay particular 4 Examine the housing cap G and spool H for signs
attention to their lips. Obtain new seals if of damage. Obtain new components if necessary.
necessary.

5 For standard handle breakers only, examine the 6 Examine the plug K, seal washer L, spring and
rubber bushes inside the handles for signs of trigger spool M for signs of damage or wear.
damage. Fit new bushes if necessary. These Obtain new components if necessary.
bushes are a press fit inside the handles and can
be removed by slitting their cores from the inside
and driving out.

9803/1250 Issue 1
C6 MAINTENANCE C6
BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED (cont’d)

7 Examine the roll pins Q, latch R, latch plunger S 8 Examine the diaphragm X for signs of damage.
and plunger spring for signs of damage or wear. Pay particular attention for signs of cracking
Obtain new components if necessary. around the diaphragm insert. Obtain a new
diaphragm if necessary.

9 Examine the bush inside the nose for signs of

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

9803/1250 Issue 1
C7 MAINTENANCE
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED
! CAUTION
Before commencing assembly, all components
must be scrupulously cleaned.
A-3-1-4
Note: During assembly, apply Multi Gasket Loctite 574
(JCB Part No. 4102/1201) to all joint faces.
2 Fit the trigger spool M, spring, seal washer L and
plug K into the head.
4 For standard handle breakers only, assemble
the top cover onto the head and fit the four
capscrews. Torque tighten the capscrews
progressively (see Introduction section), ensuring
theat the trigger pin remains free to move.
9803/1250
C7
1 Place diaphragm X into the head, ensuring that
the diaphragm insert is uppermost (as shown
above). Fit new ‘O’ ring seal Y.
3 For standard handle breakers only, insert the
trigger pin O. Assemble the trigger onto the top
cover and fit roll pins N using a press.
5 For vibro-damper handle breakers only, fit the
trigger pin O. Assemble the handle bracket onto
the head and fit the four capscrews. Torque
tighten the capscrews progressively (see
Introduction section), ensuring that the trigger
pin remains free to move.
Issue 1
C8 MAINTENANCE
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)
6 Treat thread of safety screw V with Loctite 242
and fit the safety screw into the head.
8 For vibro-damped handle breakers only, fit the
remaining handle assembly. Treat the thread of
pivot pin Z with Loctite 242 and fit the pin. Spray
the handles, trigger and all contacting parts with a
suitable lubricant.
10 For standard handle breaker only, fit the handles
to the top cover with capscrews. Torque tighten
the capscrews (see Introduction section).
9803/1250
C8
7 For vibro-damped handle breakers only, fit the
handle assembly springs. Fit the handle assembly
furthest from the trigger pin complete with pivot
pin into the handle bracket (see Step 14 of
Dismantling).
9 For vibro-damped handle breakers only,
assemble the top cover onto the handle bracket.
Treat the threads of the top cover capscrews with
Loctite 242 and torque tighten (see Introduction
section).
11 Fit the housing spool H and housing seal G into
the head. Fit a new ‘O’ ring to the housing seal.
Issue 1
C9 MAINTENANCE C9
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)

12 Assemble the seals into the lower section of the 13 Treat the thread of check valve E with Loctite 542.
barrel casting. Ensure that the open faces of the Fit the check valve and its ball F into the barrel by
seals are fitted as shown on inset. offering the check valve to the barrel from
underneath to avoid losing the ball.

14 Bolt the barrel to the nose with capscrews. Torque 15 Insert the piston C and piston feeder D into the
tighten the capscrews progressively (see barrel.
Introduction section) using a Gedore narrow
head torque wrench (part no. 7200-01). Do not
use a standard torque wrench fitted with a
universal joint as this distorts the torque setting.

16 Assemble the head assembly onto the barrel/nose 17 Assemble the plunger spring, plunger S, and latch
assembly and fit the capscrews. Torque tighten R into position in the nose. Using a press, insert
the capscrews progressively (see Introduction roll pins Q to secure the mechanism.
section) using a Gedore narrow head torque
wrench (part no. 7200-01- see Step 14 above). Fit
the hoses, ensuring that the hose with the female
coupling is fitted to the top port of the head
assembly.

9803/1250 Issue 1
C10 MAINTENANCE
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS
! WARNING
Accumulator
The breaker incorporates a pressure accumulator.
This accumulator is pressurised even when there is
no hydraulic pressure to the breaker. Attempting to
dismantle the accumulator without first releasing
the pressure can cause injury or death. This
procedure must be carried out by a qualified
person.
! CAUTION
Before commencing assembly, all components
must be scrupulously cleaned.
A-3-1-4
Note: Unless otherwise indicated, the following
instructions apply to both the ‘D’ type and ‘T’ type
breakers.
2 Cut the cable tie securing the hose gaiter 1 and
remove the gaiter. Remove the hoses 2 from the
adaptors 3. Remove the adaptors and seals 4
from the accumulator assembly.
4 If necessary, drift out the pivot pin 7 and remove
the trigger 8 from the handle.
9803/1250
C10
! WARNING
The pick must be disconnected from its source of
hydraulic power and the oil drainer before any
maintenance is carried out.
! WARNING
Under no circumstances should an attempt be
made to remove the handle when the pick is
connected to a source of hydraulic power.
1 Disconnect hoses and collect any residual oil into
a suitable container.
3 Remove the four capscrews 5 together with
washers 6 and remove the handle assembly.
5 Remove the push pin 9 (‘D’ Type only). Remove
the spring 10, trigger pin 11 and ‘O’ ring 12 from
the accumulator assembly. Discard the ‘O’ ring.
Issue 1
C11 MAINTENANCE C11
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)

6 ‘D’ Type only. Remove the retainer 13 with the
bump stop 14. Remove and discard ‘O’ ring 15.
‘T’ Type only. Remove nose latch 16 with the
shim assembly 17. Remove and discard ‘O’ ring
15.
7 ‘T’ Type only. If necessary, remove roll pins 18
and 19 suing a press. Remove the latch 20,
plunger 21 and spring 22.

8 Remove the accumulator/barrel/nose assembly 9 Apply light pressure to the top of slide rail 24 to
from the upper end of the nose casting 23. compress spring 25 then swing the bottom of the
slide rail clear of bump stop 26. Remove the slide
rail and the spring. Repeat for the other side.

10 Remove slide bearing 27 and bump stop 26 from
both sides then remove capscrews 28 to separate
the accumulator assembly from the barrel/nose
assembly.
11 Turn the accumulator assembly over. Withdraw
housing cap 29 then remove and discard ‘O’ ring
30. Remove ‘O’ ring 31 from the recess in the
accumulator assembly and discard the ‘O’ ring.
Withdraw spool 32 from the spool housing.

9803/1250 Issue 1
C12 MAINTENANCE C12
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)

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

Note: Once gas has been released, a special charging

tool (part no. 929/05800) is required to re-charge the
accumulator. Re-charging the accumulator must only
be undertaken by a suitable qualified person.
12 Remove plug 33, seal 34, spring 35 and trigger
spool 36.

13 Releasing Gas Pressure from the accumulator.
Remove the cover screw 37 to gain access to the
charging screw 38. Insert a 4 mm allen key and
slowly loosen the charging screw approximately 3
or 4 turns listening for all the gas to escape.
Tighten the charging screw approximately 3 or 4
turns. Refit the cover screw.
14 Dismantling the Accumulator Assembly (see
WARNING). Remove the four capscrews 39 and
separate the accumulator top 40 from the
accumulator head 41. Remove the diaphragm 42
from the head.

15 Hold the barrel/nose assembly above the 16 Using a suitable drift, push out the piston 45 and
workbench with the check valve housing pointing piston feeder 46 from the barrel 49. Separate the
downwards. Remove the check valve 43 with the piston from the feeder. Remove and discard ‘O’
check valve ball 44. ring 47.

9803/1250 Issue 1
C13 MAINTENANCE C13
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)

17 Remove the two grub screws 48 from the lower 18 Clamp the barrel/nose assembly in a vice and
end of the barrel 49 (one each side). unscrew the now 50 from the barrel 49, using a
‘C’ spanner.

19 Remove seal 51 and seal housing 52 from the

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

9803/1250 Issue 1
C14 MAINTENANCE
BREAKER INSPECTION - ‘D’ and ‘T’ PICKS
1 ‘T’ Type only. Examine the roll pins 18 and 19,
latch 20, plunger 21 and plunger spring 22 for
signs of damage or wear. Obtain new components
if necessary.
3 Examine the plug 33, seal 34 and trigger spool 36
for signs of damage or wear. Obtain new
ocmponents if necessary.
5 Examine the check valve ball 44 and ball seat in
check valve 43 for signs of damage or excessive
wear. Obtain new components if necessary.
9803/1250
C14
2 Examine the housing cap 29 and spool 32 for
signs of damage. Obtain new components if
necessary.
4 Examine the diaphragm 42 for signs of damage.
Pay particular attention for signs of cracking
around the diaphragm insert. Obtain a new
diaphragm if necessary.
6 Examine the piston 45, piston feeder 46 and
barrel 49. Small scratches can be carefully
removed with fine emery cloth. Deep grooves or
signs of pick-up (especially on the lower sealing
portion of the piston) will require the replacement
of the component.
Issue 1
C15 MAINTENANCE C15
BREAKER INSPECTION - ‘D’ and ‘T’ PICKS (cont’d)

7 Examine slide rails 24 and springs 25 for signs of 8 Examine slide bearings 26 and bump stops 27 for
excessive wear, damage or deformation. Replace signs of damage or excessive wear. Replace if
if necessary. necessary.

9803/1250 Issue 1
C16 MAINTENANCE C16
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS

! CAUTION
Before commencing assembly, all components
must be scrupulously cleaned.
A-3-1-4

Note: Unless otherwise indicated, the following

instructions apply to both the ‘D’ type and ‘T’ type
breakers.

Note: During assembly, apply Multi Gasket Loctite 574

(JCB Part No. 4102/1201) to all joint faces. Lightly
lubricate all hydraulic components with hydraulic fluid
prior to assembly.

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

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

2 Clamp the barrel 49 in a vice. Apply Loctite 242 to 3 Apply Loctite 242 to grub screws 48 and fit into
nose 50 and screw into the barrel using a ‘C’ the lower end of barrel 49 (one each side).
spanner.

4 Insert piston 45 into the upper end of barrel 49. Fit
new ‘O’ ring 47 to piston feeder 46 and slide the
piston feeder into the piston.
5 Treat the thread of check valve 43 with Loctite
542. Hold the barrel/nose assembly above the
workbench with the check valve housing pointing
downwards and fit the check valve with the check
valve ball 44.

9803/1250 Issue 1
C17 MAINTENANCE
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)
6 Fit the diaphragm 42 into the accumulator head
41, ensuring the diaphragm insert is uppermost.
Assembly the accumulator top 40 onto the head
and fit the four capscrews 39. Torque tighten the
capscrews to 80 Nm (8.1 kgf m, 59 lft ft).
8 Slide spool 32 into spool housing. Fit new ‘O’ ring
30 to housing cap 29 and insert into accumulator
assembly, followed by new ‘O’ ring 31.
10 Fit spring 25 and slide rail 24 as shown. Apply light
pressure to the top of the slide rail to compress
the spring then swing the bottom of the slide rail
over the bump stop 26. Repeat for the other side.
9803/1250
C17
7 Turn the accumulator assembly over. Insert
trigger spool 36 into accumulator assembly. Fit
spring 35, seal 34 and plug 33.
9 Assemble the accumulator assembly onto the
barrel/nose assembly and fit the capscrews 28.
Torque tighten the capscrews to 135 Nm (14 kgf
m, 100 lbf ft). Fit bump stops 26 to the heads of
the capscrews and assemble slide bearings 27
(both sides). Charge the accumulator, refer to
page C19.
11 Fit the accumulator/barrel/nose assembly into the
upper end of the casting 23.
Issue 1
C18 MAINTENANCE
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)
12 ‘T’ Type only. If dismantled, fit the spring 22,
plunger 21 and latch 20 into the nose latch. Using
a press, insert roll pins 18 and 19 to secure the
mechanism.
14 Lubricate a new ‘O’ ring 12 and feed it into the
hole in the top of the accumulator assembly; once
inside, the ‘O’ ring will expand to fill the groove. Fit
the trigger pin 11 and spring 10. ‘D’ type only. Fit
push pin 9.
16 Assemble the handle assembly onto the outer
casing and fit washers 6 and capscrews 5. Note
that two of the capscrews are longer than the
others.
C18
13 Fit new ‘O’ ring seal 15 onto the nose 52, taking
care not to damage it on the exposed thread. ‘T’
type only. Fit the shim assembly 17 and the nose
latch 16. ‘D’ Type only. Fit the bump stop 14 and
the retainer 13.
15 If dismantled, fit trigger 8 to the handle and drive
in pivot pin 7 to secure.
17 Assemble seals 4 and adaptors 3 to the
accumulator assembly. Fit hoses 2, ensuring that
the hose with the female coupling is fitted to the
top port of the accumulator head. Fit the hose
gaiter 1 and secure with a cable tie.
Issue 1
C19 MAINTENANCE
CHARGING THE ACCUMULATOR
! WARNING
Use only nitrogen gas to charge the accumulators.
The use of any other gas can cause the
accumulators to explode. Remember that although
Nitrogen is not poisonous, you can be killed by
suffocation if it displaces air in your workplace. Do
not allow excessive quantities of nitrogen to be
discharged into the atmosphere.
This procedure must not be carried out with the
breaker (or pick) connected to a source of
hydraulic supply.
During charging, the breaker must be securely
mounted in the upright position. This prevents the
breaker falling over whilst charging, thereby
preventing uncontrolled escape of gas.
EQUIPMENT REQUIRED
a Nitrogen bottle
Minimum residual pressure 70 bar (100 lbf/in2).
b Regulator (with contents and outlet gauge)
Outlet pressure would be controllable up to 55 bar
(800 lbf/in2)
c Charging adaptor (JCB part No. 929/05800)
together with 3/8 in. BSP Dowty washer.
d Connecting hose
Suitable hose of minimum operating pressure 207
bar (3000 lbf/in2), together with female coupling
(JCB part No. 929/06303)
CHARGING PRESSURE
The charging pressure should not exceed 50 bar (725
lbf/in2). Refer to Specification section for specific
accumulator pressures.
9803/1250
C19
CHARGING PROCEDURE
Note: For ‘D’ and ‘T’ picks, access must first be
gained to the accumulator assembly by carrying out
Steps 1 to 8 (excluding step 7) of Breaker
Dismantling.
1 Remove the slotted cover screw 1 from the
breaker.
2 Using a 4 mm Allen key 2, slowly loosen the
charging screw approximately 3 turns. Do not
remove the screw.
3 Fit the 3/8 in. Dowty washer to the charging
adaptor C and screw into the breaker. Do not
overtighten, hand tight is adequate.
4 Ensure that the nitrogen bottle outlet pressure is
at zero and then connect the charging hose D to
the charging adaptor C.
5 Gradually increase the nitrogen bottle outlet
pressure until the required level is reached (see
Specification section).
6 Push in knob 6 on the charging adaptor C to
engage the charging screw and tighten. Do not
overtighten.
7 Shut the regulator valve on the nitrogen bottle and
using the venting screw 7A, release the trapped
gas in the hose.
8 Disconnect the charging hose D and unscrew the
charging adaptor C from the body of the breaker.
9 Finally, tighten the charging screw using a 4 mm
Allen key 2 and refit the cover screw 1 after
applying Loctite 242 to the threads.
Note: For ‘D’ and ‘T’ picks, refit the accumulator
assembly by carrying out Steps 11 to 17 of Breaker
Assembly. Seals need not be replaced providing they
are serviceable.
Issue 1
C20 MAINTENANCE C20
FAULT FINDING

*The remedy in certain should be carried out by your JCB Dealer.

Symptom Possible Fault Remedy

Breaker fails to operate. No flow from supply. *Check output with flow and
pressure tester.

Hoses incorrectly fitted. Check that pressure feed is

connected to top port on the breaker.

Insufficient movement of *The trigger spool should move

trigger spool. approx. 5 mm (0.2 in). Check lever
mechanism.

Main spool jammed or *Remove and check.

damaged. Clean all associated parts.

Striker piston seized. *Remove and check for ‘pick-up’ on

piston feeder or barrel.
Replace any damaged parts.

Breaker lacks breaking power. Insufficient available pressure. *Check Main Relief Valve - for
settings refer to Specification
section.

Low accumulator gas pressure *Re-charge the accumulator as

(Normally associated with detailed in this section.
violent shaking of hoses).

Hexagon bush in nose casting Apply JCB Retainer ( High Strength )

loose. and press back.

Breaker runs slow. Insufficient flow. *Check the flow rate - for settings
refer to Specification section.

Cold oil Warm up the oil supply. Optimum

temperature 20 - 70ºC (68 - 158 ºF).

High return line back pressure. *Check return line back-pressure.

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

Incorrect oil. Use only JCB Special Hydraulic Oil

(part no. 4002/0224).

Breaker runs hot. Inadequate cooling of hydraulic Check oil supply has adequate
oil. cooling. Temperature should not
exceed 80 ºC (176 ºF).

9803/1250 Issue 1
D SPECIFICATION D
CONTENTS

JCB hydraulic breakers

Standard Breakers D1
Vibro-damped breakers D1/D2
‘D’ and ‘T’ breakers D2

Noise and vibration data D3

9803/1250 Issue 1
D1 SPECIFICATION D1
JCB HYDRAULIC BREAKERS

STANDARD BREAKERS

Breaker weight
Model Nos. 929/05400 & 05600 20 kg 44 lb
Model Nos. 929/07200 & 08200 26 kg 57 lb

Breaker length
Model Nos. 929/05400 & 05600 910 mm 36 in.
Model Nos. 929/07200 & 08200 1050 mm 41 in.

Accumulator gas pressure (Nitrogen)

Model Nos. 929/05400 & 05600 38 bar 551 lb/in2
Model Nos. 929/07200 & 08200 50 bar 725 lb/in2

Hydraulic supply flow rate

Model Nos. 929/05400, 05600 18 - 22 l/min 3.96 - 4.84 gal/min
Model No. 929/07200 18 - 22 l/min 3.96 - 4.84 gal/min
Model No. 929/08200 28 - 32 l/min 6.20 - 7.00 gal/min

Hydraulic supply pressure range

Model Nos. 929/05400 & 05600 69 - 86 bar 1000 - 1247 lb/in2
Model Nos. 929/07200 & 08200 90 - 110 bar 1300 - 1600 lb/in2

Hydraulic supply relief valve setting

Model Nos. 929/05400 & 05600 76 bar min
Model Nos. 929/07200 & 08200 1100 lb/in2 min
All models 138 bar max. 2000 lb/in2 max.

Hydraulic return line pressure 12 bar max. 174 lb/in2 max.

Breaker blow frequency 1500 blows/min -

Breaker shank size

Model No. 929/05400 22 mm 7/8 in.
Model No. 929/05600 25 mm 1 in.
Model No. 929/07200 & 08200 32 mm 1 1/4 in.

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

EHTMA Category ‘C’ or ‘D’

VIBRO-DAMPED BREAKERS

Breaker weight
Model Nos. 929/05300 & 05500 22 kg 44 lb
Model Nos. 929/07400 & 08300 28 kg 62 lb

Breaker length
Model Nos. 929/05300 & 05500 930 mm 36 in.
Model Nos. 929/07400 & 08300 1090 mm 43 in.

Accumulator gas pressure (Nitrogen) 50 bar 725 lb/in2

Hydraulic supply flow rate

Model Nos. 929/05300 & 05500 18 - 22 l/min 3.96 - 4.84 gal/min
Model No. 929/07400 18 - 22 l/min 3.96 - 4.84 gal/min
Model No. 929/08300 28 - 32 l/min 6.20 - 7.00 gal/min

9803/1250 Issue 1
D2 SPECIFICATION D2
JCB HYDRAULIC BREAKERS (cont’d)

VIBRO-DAMPED BREAKERS (cont’d)

Hydraulic supply pressure range

Model Nos. 929/05300 & 05500 69 - 86 bar 1000 - 1247 lb/in2
Model Nos. 929/07400 & 08300 90 - 110 bar 1300 - 1600 lb/in2

Hydraulic supply relief valve setting

Model Nos. 929/05300 & 05500 76 bar min. 1100 lb/in2
Model Nos. 929/07400 & 08300 117 bar min. 1700 lb/in2 min.
All models 138 bar max. 2000 lb/in2 max.

Hydraulic return line pressure 12 bar max. 174 lb/in2 max.

Breaker blow frequency 1500 blows/min -

Breaker shank size 32 mm 1.25 in.

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

EHTMA Category ‘C’ or ‘D’

‘D’ and ‘T’ BREAKERS

Breaker weight (Dry with hoses)

‘D’ Handle 12 kg 26.4 lb
‘T’ Handle 14 kg 28.6 lb

Breaker length
‘D’ Handle 645 mm 25.4 in.
‘T’ Handle TBA mm TBA in.

Accumulator gas pressure (Nitrogen) 33 bar 480 lb/in2

Hydraulic supply flow rate 15 - 20 litre/min 3.3 - 4.5 gal/min

Hydraulic supply pressure range 50 - 65 bar 725 - 945 lb/in2

Hydraulic supply relief valve setting TBA bar min. TBA lb/in2 min.
TBA bar max. TBA lb/in2 max.

Hydraulic return line pressure TBA bar max. TBA lb/in2 max.

Breaker blow frequency 1500 blows/min -

Breaker shank size 2.22 mm 0.875 in.

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

ETHMA Category ‘C’

9803/1250 Issue 1
D3 SPECIFICATION D3
NOISE AND VIBRATION DATA

Model No. Handle Type Noise Level EC Vibration Weighted

Directive 84/457/ RMS Acceleration ISO
EEC (LWA) 8662 Part 5 (m/s2)

929/05300 Vibro-Damped 111 5.5

929/05400 Standard 111 18.9

929/05500 Vibro-Damped 111 5.5

929/05600 Standard 111 18.9

929/07400 Vibro-Damped 107 5.4

929/07200 Standard 107 16.6

929/08300 Vibro-Damped 108 6.0

929/08200 Standard 108 17.1

929/12900 ‘D’ Type 103 5.7

929/20400 ‘T’ Type 103 5.7

9803/1250 Issue 1
E1 CONTENTS E1
HYDRAULIC POWER PACKS
SAFETY FIRST - YOURS AND OTHER PEOPLE’S

Safety first - yours and other peoples E2

Safety check list E2

Lubricants - Health and Safety E4

Identifying your machine E5

Hydraulic Powerpacks E6

Engine and electrical system E7

Hydraulic circuits E8

9803/1250 Issue 1
E2 INTRODUCTION
HYDRAULIC POWER PACKS
SAFETY FIRST - YOURS AND OTHER PEOPLE’S
All hydraulic equipment can be hazardous. When a hydraulic
powerpack is correctly operated and properly maintained, it
is a safe machine to work with. But when correct operation
and maintenance routines are not followed, the machine can
be a danger to you (the operator) and others.
In this handbook and on the machine you will find warning
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not
understand the warning messages, ask your employer or
JCB Dealer to explain them.
SAFETY CHECK LIST
GENERAL SAFETY
! WARNING
Handbook
You and others can be injured if you operate or maintain the
machine without first studying this handbook. Read the
instructions before operating the machine. If there is
anything that you do not understand, ask your employer or
JCB Dealer to explain it. Keep this handbook clean and in
good condition. Do not operate the machine without a
handbook readily available or if there is anything on the
machine that you do not understand.
! WARNING
Decals
You can be injured if you do not obey the decal safety
instructions. Keep decals clean. Renew unreadable and
missing decals before operating the machine. Make sure
replacement parts include warning decals where necessary.
OPERATING SAFETY
! WARNING
Machine Condition
A defective machine can injure you or others. Do not operate
a machine which is defective or has missing parts. Make
sure the maintenance procedures in this handbook are
complete before using the machine.
! WARNING
Hydraulic Tools
Hydraulic tools can be dangerous. Observe all safety
instructions relevant to the tool you will be operating. If in
any doubt, consult you JCB Dealer.
9803/1250
E2
But safety is not just a matter of responding to the warnings.
All the time you are working on or with the machine you
must be thinking what hazards there might be and how to
avoid them.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember BE CAREFUL
BE ALERT
BE SAFE
! WARNING
Clothing
You can be injured if you do not wear correct clothing. Loose
clothing can get caught in the machinery. Wear protective
clothing to suit the job. Examples of protective clothing are:
hard hat, safety shoes, safety glasses, a well fitting overall,
ear protectors and industrial gloves. Keep cuffs fastened. Do
not wear a necktie or scarf. Keep long hair restrained.
! WARNING
Care and alertness
All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
hazards.
! WARNING
Regulations
Obey all laws, worksite and local regulations which affect
you and your machine.
! WARNING
Practice
You or others can be killed or seriously injured if you do
unfamiliar operations without first practicing them. Practice
away from the worksite on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
! WARNING
Exhaust Gasses
Breathing the machine exhaust gases can harm and possibly
kill you. Do not operate in closed spaces without making
sure there is good ventilation.
Issue 1
E3 INTRODUCTION E3
HYDRAULIC POWER PACKS
SAFETY CHECK LIST (continued)
! WARNING ! WARNING
Communications Petrol
Bad communications can cause accidents. Keep people Petrol is flammable; keep naked flames away from the
around informed of what you will be doing. If you will be machine. Do not smoke while refuelling the machine or
working with other people, make sure any hand signals that working on the engine. Do not refuel with the engine
may be used are understood by everybody. Work sites can running. There could be a fire and injury if you do not follow
be noisy, do not rely on spoken commands. these precautions.

! WARNING
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in a
closed area where there is flammable material, vapour or
dust.
! WARNING
Hot Surfaces
Under normal working conditions the engine components,
particularly the exhaust system, will get hot - DO NOT
TOUCH.
The hydraulic oil, pump, valve and tank can also reach
temperatures high enough to burn - DO NOT TOUCH.
! WARNING
Noise
Excessive noise can be hazardous to your health. Always
wear ear defenders when operating the machine.
! WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
! WARNING
Fires
Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use carbon
dioide, dry chemical or foam extinguishers. Contact your
nearest Fire Department as quickly as possible. Firefighters
should use self-contained breathing apparatus.
! WARNING
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:

Damaged end fittings

Chafed outer covers
Ballooned outer covers
MAINTENANCE SAFETY Kinked or crushed hoses
Embedded armouring in outer covers.

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

! WARNING
Modifications
Non-approved modifications can cause injury and damage.
Contract your JCB Dealer before modifying the machine.

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

9803/1250 Issue 1
E4 INTRODUCTION E4
HYDRAULIC POWER PACKS
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand this First Aid
information and the publications referred to. Make sure that
all of your colleagues who are concerned with lubricants
Swallowing
read it too.
If oil is swallowed do not induce vomiting. Get medical
advice.
Hygiene
JCB lubricants are not a health risk when used properly for Eyes
their intended purpose. In the case of eye contact, flush with water for 15
minutes. If irritation persists get medical attention.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and irritation. Skin
In the case of excessive skin contact, wash with soap
Low viscosity oils are more likely to do this, so take special and water.
care when handling used oils which may be diluted with fuel
contamination.
Spillage
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For Absorb on sand or a locally approved brand of
details of these precautions we advise you to read the absorbent granules. Scrape up and remove to a
relevant publications issued by your Local Health Authority, chemical disposal area.
plus the following.

Storage Fires

Always keep lubricants out of reach of children. Never store
lubricants in open or unlabelled containers.
Handling
New Oil
There are no special precautions needed for the handling or
use of new oil, beside the normal care and hygiene practices.
Used Oil
Used oils contain harmful contaminants. Here are pre
cautions to protect your health when handling used oil.
1 Avoid prolonged, excessive or repeated skin contact
with used oil.
Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self -contained breathing
apparatus.
Waste Disposal
All waste products should be disposed of in
accordance with the relevant regulations.
The collection and disposal of used oil should be in
accordance with any local regulations. Never pour
used oil into sewers, drains or on the ground.

2 Apply a barrier cream to the skin before handling used

oil.

3 Note the following removing oil from the skin:

a Wash your hands thoroughly with soap and water.

b Using a nail brush will help.

c Use special hand cleansers to help clean dirty

hands.

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

e Avoid skin contact with oil soaked clothing.

f Do not keep oily rags in pockets.

g Wash dirty clothing before reuse.

h Throw away oil soaked shoes.

9803/1250 Issue 1
E5 INTRODUCTION E5
HYDRAULIC POWER PACKS
IDENTIFYING YOUR MACHINE
Machine Serial Number Engine Serial Number
Your machine is stamped with a serial number. The machine The engine will also have a serial number. Its position
serial number can help you to find out what type of depends on which model you are operating. Consult your
equipment you have. Your machine is stamped with both engine manufacturer’s handbook for details.
model and serial number and they can be found on top of
the spacer plate X between the engine and hydraulic tank.
On Trojan III, Robin diesel engine models, the serial number
can be found on pump mounting plate above the pump.

On all machines, the model number A is the first group of

eight digits and the serial number B is the second group of
seven digits.

C009340

9803/1250 Issue 1
E6 INTRODUCTION E6
HYDRAULIC POWER PACKS

The range of hydraulic powerpacks are categorised by General Description

EHTMA as Category ‘C’ or ‘D’ hydraulic powerpacks and
can be safely used with any hydraulic tool displaying the
EHTMA ‘C’ or ‘D’ decals as shown below.
The JCB Hydraulic powerpacks have been specially
developed to provide a lightweight source of portable
hydraulic power for the JCB handheld hydraulic breakers
and tools.

c D
Despite their simple construction, the powerpacks
incorporate many special features such as automatic,
energy saving, engine speed control, a variable hydraulic
flow and a unique hydraulic circuit design (patent applied
for) which eliminates totally any possibility of pulsation
20LPM AT 138 BAR 30LPM AT 138 BAR
ETHMA CATEGORY ETHMA CATEGORY damage to the oil cooler.

TO AVOID RISK OF INJURY TO AVOID RISK OF INJURY All the major components are enclosed in a fully welded
CONNECT ONLY TO CATEGORY CONNECT ONLY TO CATEGORY
"D" POWERPACKS
tubular frame which also provides easy hand holds to
"C" POWERPACKS
maximise portability. A balanced lifting point is also
provided.

This manual covers the JCB BEAVER III, Compact III,

! WARNING
You must understand and follow the instructions in this
manual and any accompanying manuals. If you are
unsure about anything ask your dealer or employer. Do
not guess, or you or others could be killed or seriously
injured.
Trojan III, Duopower III and Micro Powerpacks. to
operate the powerpack efficiently and safely you must know
the powerpack and have the skill to use it. It is assumed that
personnel carrying out maintenance have at least a sound
knowledge of workshop practice, safety procedures and
general techniques associated with the repair of hydraulic
equipment.
Note: It is important to quote the serial number when
making repairs or ordering parts.

9803/1250 Issue 1
E7 INTRODUCTION E7
HYDRAULIC POWER PACKS
ENGINE AND ELELCTRICAL SYSTEM
Engine Electrical System
The hydraulic powerpacks are fitted with different engines to The electrical system is a 12V negative earth system. The
give rated outputs as follows: machine is fitted with a single 12V battery.

Model Type Performance Consult the Engine Manufacturer’s Handbook for details of
the engine electrical circuits.
Beaver III Honda GX240 8 HP (6 kW)
Suzuki V270 9 HP (6.7 kW)
Yanmar L70E 7 HP (5.2 kW)
Lombardi 15LD 6.7 Hp (5 kW)

Compact III Honda GX160 5.3 HP (4 kW)

Trojan III Robin DY 35D 8 HP (6 kW)

Yanmar L100AE 10 HP (7.5 kW)
Honda GX340 11 Hp (8.2 kW)
Honda GX390 13 Hp (9.7 kW)

Micro Honda GX160 5.3 Hp (4 kW)

Duopower III Briggs and Stratton

Vanguard 18 HP (13.4 kW)

The performance figures quoted are produces at a speed of

3600 rev/min (maximum permissible engine speed).

Engine speed is controlled automatically by a small hydraulic

ram which is activated by the hydraulic circuit oil pressure.

9803/1250 Issue 1
E8 INTRODUCTION E8
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUITS
Description
Bearer III and Compact III powerpacks are fitted with an
hydraulic circuit capable of delivering 0 - 20 litres/min. Trojan
III powerpacks are fitted with either a 0 - 20 litres/min or a 0 -
30 litres/min. hydraulic circuit depending on the model
number. Duopower III powerpacks provide two independent
variable flow outputs at 0 - 20 litres/min. which can be
combined to give a single 0 - 40 litres/min. output. Full
details are provided in Section D - Specification.

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

20 Litres/min Hydraulic Circuit

The reservoir for the circuit is the hydraulic oil tank T, which
contains a suction filter B, to prevent any dirt particles from
being drawn into the pump D and return filter A to strain the
returning oil. Hydraulic oil is drawn from the tank T, through
the oil cooler C by the engine driven hydraulic pump D.

The hydraulic circuit is self governing in that, although the

pump output is directly proportional to the speed of the
engine, the system pressure is related only to the power
demanded to push the oil around the circuit and operate
whatever tool is connected.

Oil from the hydraulic pump D is fed under pressure to a

control valve which consists of two main parts:

a A relief valve E which controls the maximum working

pressure of the system (see Operation Section).

b An output control valve F which directs the flow of oil

either to the tool or back to the hydraulic tank T.

30 Litres/min Hydraulic Circuit

In these hydraulic circuits, extra components are fitted to

prevent damage occurring to the hydraulic pump. An
additional suction filter B is fitted to feed an anti-cavitation
tee G. The anti-cavitation tee ensures that the negative
pressure generated at the pump suction does not drop low
enough for cavitation to occur.

As with the 20 litres/min powerpacks, the hydraulic circuit is

also self-governing and the operation is similar.

9803/1250 Issue 1
E9 INTRODUCTION
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUITS (continued)
Description (continued)
Duopower 40 Litres/min Hydraulic Circuit
The reservoir for the circuit is the hydraulic oil tank T which
contains suction filters B to prevent any dirt particles from
being drawn into the pumps D, and return filter A to clean
the returning oil.
Hydraulic oil is drawn from the tank T, through the oil cooler
C by the engine driven pumps D.
The 20 litres/min flow of hydraulic oil from each pump D is
fed to control valves E and F. when the stop valve G is
closed (lever to the left), each control valve will supply
between 0 and 20 litres/min, the output control lever of each
valve selecting the individual flows independant of each
other.
9803/1250
E9
To provide 40 litres/min maximum from control valve E
(upper valve on the power pack(, the stop valve G must be
opened (lever to the right). Control valve F must be set to 20
litres/min using the output control lever and no connection
should be made to the quick release couplings on this valve.
Oil from the front section of the pump D is fed via the open
stop valve G, through the check valve H and combines with
the flow from the rear pump into the directional flow valve E.
The returning oil from each control valve is combined at the
return manifold J, and then to the tank T via the return filter
A.
Issue 1
E10 OPERATION E10
HYDRAULIC POWER PACKS
CONTENTS

Introduction E11

Before operating the machine E11

Before starting the engine E11

Honda GX160, GX240, GX340 and GX390 engines:

Starting and stopping E12

Suzuki V270 engines:

Starting and stopping E13

Yanmar L70E and L100E engines:

Starting and stopping E14

Lombardi 15LD315 engines:

Starting and stopping E15

Robin DY35D engine:

Starting and stopping E16

Briggs and Stratton Vanguard engine:

Starting and stopping E17

Operating in low temperatures E18

Operating in high temperatures E18

Hydraulic output control and feed and return

connectors E18

Connecting/disconnecting hoses E19

9803/1250 Issue 1
E11 OPERATION
HYDRAULIC POWER PACKS
INTRODUCTION
This chapter is arranged to guide you step-by-step through
the task of learning how to operate the machine. Read it
through from beginning to end. By the end of the chapter
you should have a good understanding of the machine and
how to operate it.
Pay particular attention to all safety messages. They are to
warn you of possible danger. Do not just rear them; think
about what they mean. Understand the dangers and how to
avoid them. If there is anything you do not understand, ask
you JCB Dealer. He will be pleased to advise you.
Before Operating the Machine
The following checks should be made each time you return
to the machine after leaving it for a period of time. All these
checks concern the serviceability of the machine. Some
concern your safety.
1 Check for Cleanliness
a Remove dirt and debris, especially from around the
linkages, rams and hydraulic oil cooler.
b Clean all safety decals. Replace any that are mssing
or cannot be read.
2 Check for Damage
a Inspect the machine and hoses generally for signs
of damage and missing parts.
b Check for fluid and fuel leakages beneath the
machine.
3 Check for Security
a Check the security of the hinged frame.
b Make sure the fuel filler cap is tightly closed.
4 Check Hydraulic Oil Level
a Check the hydraulic oil level and add as necessary.
9803/1250
E11
When you have learned where the controls are and what
they do, practise using them. Practise using the machine is a
safe place, clear of other people. Get to know the ‘feel’ of
the machine and its controls.
Finally, do not rust the job of learning. Take you time and
talk it safely.
Remember BE CAREFUL
BE ALERT
BE SAFE
Before Starting the Engine
Note: If you will be operating the machine in either very cold
or very hot conditions, refer to Operating in Low
Temperatures or Operating in High Temperatures.
1 Position the Machine
a Ensure the machine is positioned safely.
2 Complete a Pre-start Inspection
a If you have not already done so, complete a pre-
start inspection. Refer to Before Operating the
Machine (opposite).
b Ensure that all hydraulic couplings are fully
serviceable. Refer to Hydraulic Couplings.
c Ensure that any hydraulic tools you are planning to
use are compatible with the model of the machine
you are using, see Specification.
3 Check Engine Oil Level
a Check the engine oil level and add oil as necessary.
4 Check Hydraulic Oil Level
a Ensure that you have adequate fuel for the job. Top
up the fuel tank as necessary, taking care not to
overfill. Never refuel with the engine running.
Issue 1
E12 OPERATION E12
HYDRAULIC POWER PACKS
HONDA GX160, GX240, GX340 AND GX390 ENGINES
Starting

1 Complete the Before Operating the Machine and

Before Starting the Engine procedures given on page
E11.

2 On recoil start machines, turn the engine switch A to the

‘On’ position.

3 Turn on the fuel by setting the fuel On/Off control B to

the ON position.

4 Move the choke control C to the CLOSE position.

If the engine is warm or the air temperature is high, the

choke control should be set to the OPEN position.

5 Set the hydraulic output control (see page E18) to the

OFF position.

6 Recoil Start Models

Pull the starter grip E lightly until resistance is felt, then

pull briskly. Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage.

Electric Start Models

Turn the keyswitch A to the ‘Start’ position and hold it

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

When the engine starts, allow the keyswitch A to return

to the ‘Run’ position.

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

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

7 As the engine warms up, gradually move the choke

control C to the OPEN position.

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

the required hydraulic output.

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

2 Turn off the fuel by setting the fuel on/Off control B to

the OFF position.

9803/1250 Issue 1
E13 OPERATION E13
HYDRAULIC POWER PACKS
SUZUIK V270 ENGINES
Starting
1 Complete the Before Operating the Machine and
Before Starting the Engine procedures given on page
E11.

2 Turn on the fuel by setting the fuel On/Off control A to

the ON position.

3 Move the choke control B to the left when the engine is

cold.

If the engine is warm or the air temperature is high,

leave the choke control in the right hand position.

4 Set the throttle control C to the FAST position.

5 Set the hydraulic output control (see page E18) to the

OFF position.

6 Pull the starter grip lightly until resistance is felt, then

pull briskly. Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage.

7 As the engine warms up, gradually return the choke

control B to the right.

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

the required hydraulic output.

Stopping
1 Set the throttle control C to the SLOW position.

2 Turn off the fuel by setting the fuel On/Off control A to

the OFF position.

9803/1250 Issue 1
E14 OPERATION E14
HYDRAULIC POWER PACKS
YANMAR L70E AND L1003 ENGINES
Starting
1 Complete the Before Operating the Machine and
Before Starting the Engine procedures given on page
E11.

2 Turn on the fuel by setting the fuel On/Off control A to

the ON position.

3 Set the engine speed control B to the RUN/START

position and tighten the knob to lock in this position.

4 Set the hydraulic output control (see page E18) to the

OFF position.

5 Start the engine as follows:

Recoil Start Models

Use the starter grip D to turn the engine over until

compression is reached, then push down the
decompressor control C.

Pull the starter grip D briskly. Do not allow the starter

grip to snap back against the engine. Return it gently to
prevent damage.

Electric Start Models

Insert the key E, turn to the ‘Start’ position and hold it

there until the engine starts. Do not use the electric
starter for more than 10 seconds at a time. If the engine
fails to start , release the key and wait 15 seconds
before operating the starter again.

When the engine starts, return the key to the ‘Run’

position. Do not remove the key.

6 After starting, allow the engine to idle for a few minutes

then slacken the engine speed control B.

Temperature Idling Time

Below - 20 ºC 5 minutes
- 20 ºC to - 10 ºC 2 minutes
- 10 ºC to 5 ºC 1 minute
above 5 ºC 20 seconds

In cold weather if your engine is hard to start, remove

rubber plug E and add 2 c.c. of engine oil before
starting.

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

the required hydraulic output.

Stopping
1 Move the speed control B to the STOP position.

2 If an electric start motor, turn the key F to the ‘Off’

position and remove from the switch.

3 Turn off the fuel by setting the fuel On/Off control A to

the OFF position.

9803/1250 Issue 1
E15 OPERATION E15
HYDRAULIC POWER PACKS
LOMBARDINI 15LD315 ENGINE
Starting
1 Complete the Before Operating the Machine and
Before Starting the Engine procedures given on page
E11.

2 Set the engine speed at 50% by slackening wingnut C

and setting the throttle control A approximately mid-
way between the MIN and MAX marks. Tighten the
wingnut C.

3 Set the hydraulic output control (see page E18) to the

OFF position.

4 Recoil Start Models

Pull the starter grip D lightly until resistance is felt, then

pull briskly. Do not allow the starter grip to snap back
against the engine. return it gently to prevent damage.

Electric Start Models

Insert the key in the control panel. When the key is

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

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

5 After starting, allow the engine to idle for a few minutes

then slacken wingnut C.

Temperature Idling Time

Below - 20 ºC 5 minutes
- 20 ºC to - 10 ºC 2 minutes
- 10 ºC to 5 ºC 1 minute
above 5 ºC 20 seconds

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

the required hydraulic output.

Stopping
1 Set the stop lever B to the STOP position.

2 If an electric start model, turn the key to the OFF

position and remove it from the control box.

9803/1250 Issue 1
E16 OPERATION E16
HYDRAULIC POWER PACKS
ROBIN DY 35D ENGINE
Starting
1 Complete the Before Operating the Machine and
Before Starting the Engine procedures given on page
E11.

2 Turn the engine Start/Stop switch A to the START

position.

3 Turn on the fuel by setting the fuel On/Off control B to

the ON position.

4 Set the hydraulic output control (see page E18) to the

OFF position.

5 Recoil Start Models

Pull the starter grip C lightly until resistance is felt, then

pull briskly. Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage.

Electric Start Models

Turn the starter key D to the START position and hold it

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

When the engine starts, release the key and allow to

return to the RUN position.

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

the desired hydraulic output.

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

2 If an electric start model, turn the key D to the STOP

position and remove from the switch.

3 turn off the fuel by setting the fuel On/Off control B to

the OFF position.

9803/1250 Issue 1
E17 OPERATION E17
HYDRAULIC POWER PACKS
BRIGGS & STRATTON VANGUARD ENGINE
Starting 8 As the engine warms up, gradually return the choke
control A to the RUN position.
1 Complete the Before Operating the Machine and
Before Starting the Engine procedures given on page 9 Set the throttle control C to give the desired engine
E11. speed.

2 Set the choke control A to the CHOKE position. If the 10 Set the hydraulic output control (see page E18) to give
engine is warm or the air temperature is high, the choke the required hydraulic output.
control should be set to the RUN position.

3 Turn on the fuel by setting the fuel shut-off control B to Stopping

the ON (horizontal) position.
1 Set the rocker switch to the OFF position.
4 Set the throttle control C to the SLOW position.
2 Turn off the fuel by setting the fuel shut-off control B to
5 Set the hydraulic output control (see page E18) to the the OFF (vertical) position.
OFF position.
3 If an electric start model, turn the starter key to the OFF
6 Set the rocker switch to the ON position. position and remove from the switch.

7 Recoil Start Models

Pull the starter grip D lightly until resistance is felt, then

pull briskly. Do not allow the starter grip to snap back
against the engine. Return it gently to prevent damage.

Electric Start Models

Insert the key in the keyswitch. Turn the key to the

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

When the engine starts, release the key.

9803/1250 Issue 1
E18 OPERATION
HYDRAULIC POWER PACKS
OPERATING IN HIGH AND LOW TEMPERATURES
Operating in Low Temperatures
In low temperature situations, take the following precautions.
They will make for easier starting and prevent possible
damage to your machine.
1 Use the Correct Viscosity Engine Oil
See Engine Manufacturer’s Handbook.
2 Keep the Battery at Full Charge
3 Fill the Fuel tank at the End of each Working Period
E18
Operating in High Temperatures
In high temperature situations, take the following
precautions to prevent possible damage to the machine
1 Use the Correct Viscosity Engine Oil
See Engine Manufacturer’s Handbook.
2 Keep the Hydraulic Oil Cooler Clean
Regularly remove dirt and debris from the hydraulic oil
cooler, particularly from around the air inlets.

4 Protect the Machine When not in use 3 Ensure Free Flow of Air to the Engine

Put the machine inside a building or cover it with a
tarpaulin.
Note: If the machine is to be used continually at
temperatures below 0 ºC consult your JCB Dealer.
As the engine on the machine is air cooled it is
necessary to ensure that the machine is positioned so
as not to restrict the flow of fresh air to the engine.

HYDRAULIC OUTPUT CONTROL AND CONNECTORS

Beaver III, Compact III and Trojan III

Hydraulic output control 1 is used to control the flow rate to
the tool in use.

Connectors 2 and 3 are used to connect the powerpack to

the tool as follows:

Connector 2 - Feed (male)

Connector 3 - Return (female)

Duopower III
Hydraulic output control 1 is used to control the flow rate to
the tool connected to the top couplings 4 and 5. This (main)
output can be 0 - 20 litres/min or 0 - 40 litres/min, depending
on the position of flow rate selector control 3. Note: The illustration above shows a Beaver III hydraulic
powerpack, however, the layout is similar for the Compact III
Hydraulic output control 2 is used to control the flow rate to and Trojan III and Micro machine.
the tool connected to the lower coupling 6 and 7. this
(secondary) output is 0 - 20 litres/min.

When in the left-hand position, flow rate selector control 3

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

Connectors 4 and 7 are used to connect the main and

secondary circuits to the tool in use as follows:

Connector 4 - Main circuit feed (male)

Connector 5 - Main circuit return (female)
Connector 6 - Secondary circuit feed (female)
Connector 7 - Secondary circuit return (male)

9803/1250 Issue 1
E19 OPERATION E19
HYDRAULIC POWER PACKS
CONNECTING/DISCONNECTING THE HOSES
! CAUTION
Ensure that any tools that you are planning to use are
compatible with the model of powerpack you are using.
See Specification Section.

Connecting Hoses
1 Prepare the Machine

a Stop the engine.

b Move the output control to mid position.

2 Inspect the Couplers

Ensure that all couplers are clean and serviceable. See

Maintenance Section.

3 Connect the Hoses

a Attach the return line.

b Attach the feed line.

Note: The connector is locked when the collar is turned

away from the ball.

4 Check the Hydraulic Oil Level

a Start the engine and run the machine to fill up the

hydraulic circuit.

b Check the hydraulic oil level (see Checking the

Hydraulic Oil Level in the Maintenance Section.

Disconnecting Hoses
1 Prepare the Machine

a Stop the engine.

b Move the output control to mid position.

2 Remove the Hoses

a Release the feed line.

b Release the return line.

Note: The connectors are unlocked by moving the collar

back on the connect.

9803/1250 Issue 1
E20 OPERATION E20
HYDRAULIC POWER PACKS
CONTENTS

Regular maintenance schedules E21

Hydraulic couplings E22

Hydraulic hoses E22

Cleaning the machine E22

Checking for damage E22

Hydraulic circuit E22

Gaining access to machine components E26

Fluids, lubricants, capacities and specification E26

Hydraulic circuit - engine speed and relief valve adjustment

Beaver III, Compact III and Trojan III E27

Duopower III E29

Battery E32

Fault finding E33

Note: For engine maintenance see Engine Manufacturer’s

Handbook.

9803/1250 Issue 1
E21 MAINTENANCE E21
HYDRAULIC POWER PACKS
REGULAR MAINTENANCE SCHEDULES
A poorly maintained machine is a hazard. Doing regular Every 3 Months
maintenance and lubrication jobs listed in these schedules
will help keep the machine in safe working order. 1 Do the Daily jobs plus:

Apart from the daily jobs, the schedules are based on 2 Clean
machine running hours. Keep a regular check of hours in
use. Do not use a machine which is due for a regular service. a Air cleaner elements
Rectify any defects found during regular maintenance before (see Engine Manufacturer’s Handbook).
clearing the machine for use.
b Engine oil filter.
! WARNING
Maintenance must be done only by suitably qualified and 3 Change
competent persons.
a Engine oil
Before doing any maintenance, make sure the machine is
safe and correctly sited on level ground. b Hydraulic filter

Daily c Hydraulic oil

1 Clean Every 6 Months

Machine generally. 1 Do the Daily and 3-monthly jobs plus:

2 Check 2 Check

a Generally for damage. a tightness of nuts, bolts, screws and hose fittings.

b Hydraulic fluid level. b Flow and pressure output.

c Engine oil level. 3 Change

d Hydraulic couplings. a Main hydraulic filter.

e Hydraulic hoses. b Hydraulic fluid.

Note: Check tightness of nuts, bolts, screws and hose c Engine oil.
fittings after the first days operation and thereafter in (see Engine Manufacturer’s Handbook).
accordance with the Maintenance Schedule.
4 Clean
Note: The engine oil should be replaced after the first three
days operation and thereafter in accordance with the a Fuel strainer.
Maintenance Schedules.
b Spark plug - Petrol models only.

5 Check

a Spark plug gap - Petrol models only.

Note: For detailed maintenance procedure, refer to Engine

Manufacturer’s Handbook.

9803/1250 Issue 1
E22 MAINTENANCE
HYDRAULIC POWER PACKS
HYDRAULIC COUPLINGS
The JCB Hydraulic Powerpacks are fitted with quick-release
hydraulic couplings to allow the operator to remove and
install attachments swiftly and efficiently. The couplings
should be trouble free and relatively easy to connect and
disconnect, provided they are kept clean and used correctly.
The following guidelines should be followed:
1 Before making a connection, wipe the two faces of the
coupling and ensure that they are clean.
2 When disconnecting, ensure that the outside sleeve is
pulled back.
3 When using a new coupling, connect and disconnect
several times to ‘work’ the P.T.F.E. seals. This will
prevent the seal ‘sticking’.
4 Do not attempt to reconnect using a damaged half-
coupling as this will destroy the seals and necessitate
replacing both halves.
5 Do not leave the coupling where it can be run over or
otherwise crushed as this can distort the sleeve and
make correct connection and disconnection impossible.
HYDRAULIC HOSES
Note: Hoses displaying any of the following damage must
not be used and should be replaced immediately.
1 End fitting damaged or leaking.
2 Outer covering chafed or cut and wire re-inforcing
exposed.
3 Outer covering ballooning locally.
CLEANING THE MACHINE
Clean the machine using water and/or steam. Do not allow
mud to build up on the engine. Make sure that the air inlets
on the hydraulic cooler are not clogged.
9803/1250
E22
6 When fitting adaptors to the coupling, always clamp
using the hexagon provided. Do not attempt to clamp
or use an adjustable spanner on the sleeve as this will
distort it.
7 Never try to turn the sleeve when disconnected as the
locking ball will jam underneath the sleeve and destroy
the coupling.
8 If a coupling sticks, which may occur if dirt is present
through neglect, then only a hide or rubber hammer
should be used to aid disconnection.
9 Care must be take to ensure that the faces of the
coupling do not become damaged as this can prevent
proper connection and disconnection or damage the
seals and cause leakage.
10 Do not attempt to strip down and service a damaged
coupling as there are not serviceable parts. Always
replace damaged couplings.
11 Only use couplings as supplied by JCB since the fitting
of inferior makes can cause damage and will invalidate
any warranty.
12 Ensure that the hydraulic filter has been properly
maintained. This will prevent oil contamination from
damaging the couplings.
4 Evidence of kinking or crushing on flexible part of hose.
5 Armouring embedded in outer cover.
6 End fittings displaced.
7 Chafing of hoses.
Note: Hoses must not be twisted. Replace any broken hose
straps to avoid damaging hoses.
CHECKING FOR DAMAGE
1 Check framework for damage.
2 Check machine generally for obvious signs of damage.
3 Ensure that all safety and operating decals are
undamaged and legible.
Issue 1
E23 MAINTENANCE E23
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT
Checking the Hydraulic Fluid Level
1 Prepare the Machine

Position the machine on level ground. Switch off the

engine and allow it to cool down.

2 Check the Hydraulic Fluid Level

a Check the hydraulic fluid level using sight gauge A.

b If necessary top up the hydraulic fluid through filler

B.

Note: Use only the recommended hydraulic fluid.

Changing the Hydraulic Fluid

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

1 Prepare the Machine

Position the machine on level ground. Switch off the

engine and allow it to cool down.

2 Drain the Hydraulic Fluid

a Place a container of a suitable size below the tank

drain plug C to catch the fluid.

b Remove drain plug C and filler cap B and allow fluid

to drain out.

3 Replace the Hydraulic Fluid

a Clean and refit drain plug C.

b Pour fluid through filler until it reaches the required

level on sight gauge A.

c Refit filler cap B.

Note: Use only the recommended hydraulic fluid.

9803/1250 Issue 1
E24 MAINTENANCE E24
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT (continued)
Changing the Main Hydraulic Filter

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

Note: On Duopower III powerpacks, the hydraulic filter is

mounted on top of the hydraulic tank.

1 Prepare the Machine

Position the machine on level ground. Switch off the

engine and allow it to cool down.

Place a container of suitable size beneath the filter to

catch any spilt fluid.

2 Remove Used Filter

a Remove the three bolts A securing the lid to

hydraulic filter housing B, and remove the lid.

b Lift out and dispose of the used filter.

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

3 Fit New Filter

a Push the new element C firmly into place in the filter

housing B.

b Refit the lid on the filter housing B, ensuring that

spring clip D located between spigots E. Secure
with the three bolts A.

4 Check the Hydraulic Fluid Level

Check the hydraulic fluid level, see Checking the

Hydraulic Fluid Level.

9803/1250 Issue 1
E25 MAINTENANCE E25
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT (continued)
Cleaning the Oil Cooler

The oil cooler fins may be cleaned using low pressure

compressed air. Do not attempt to clean using a wire brush
as this could damage the fins.

Replacing the Oil Cooler

1 Remove the hoses

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

a Loosen the jubilee clips and remove the hoses A.

2 Remove the Cooler

a Undo the eight bolts B and remove the guard C.

b Remove and dispose of the damaged cooler.

3 Reassemble

a Clean the guard and refit it and the new cooler.

b Push the cooler up to the fan housing and ensure an

airtight fit. Replace and tighten the eight bolts B.

4 Replace the Hoses

a Apply sealant to the threads and cores on the hoses.

Refit the hoses and tighten the fittings using two
spanners.

5 Run and Test

a Run the machine and top up hydraulic fluid as

necessary.

b Ensure that the machine functions correctly.

Note: Ensure that all fittings are airtight, allowing no air to be

sucked into the hydraulic fluid circuit.

9803/1250 Issue 1
E26 MAINTENANCE E26
HYDRAULIC POWER PACKS
GAINING ACCESS TO MACHINE COMPONENTS
To facilitate easier maintenance, the tubular frame is fitted
with hinge bolts. The frame may be moved to afford ready
access to the machine components in the following manner:

1 Remove Securing Clips

Remove and retain securing clips A.

2 Move the Frame

Lift the tubular frame out of the way of the machine

components by hinging it on bolts B.

Note: It is important that after maintenance, the tubular

frame is restored to its operating position and that the clips A
are securely fitted.

Note: When the machine is to be lifted using the balanced

lifting point C, it is important to ensure that the clips A are in
place and securely fitted.

FLUIDS, LUBRICANTS, CAPACITIES AND SPECIFICATION

ITEM CAPACITY FLUID/LUBRICANT

Litres (UK gal)

Engine (Oil) Refer to Manufacturer’s Refer to Manufacturer’s

handbook as supplied. handbook as supplied.

Fuel Tanks:

Honda GX160 3.6 (0.79) Unleaded petrol

Honda GX240, GX340, GX390 6.0 (1.32) Unleaded petrol
Suzuki V270 6.5 (1.43) Unleaded petrol
Yanmar L70E 3.5 (0.77) Refer to Manufacturer’s Handbook
Yanmar L100E 5.5 (1.45) Refer to Manufacturer’s Handbook
Lombardini 15LD 4.3 (0.95) Refer to Manufacturer’s Handbook
Robin DY 35D 6.0 (1.32) Refer to Manufacturer’s Handbook
Briggs & Stratton Vanguard 8.5 (1.87) Refer to Manufacturer’s Handbook

Hydraulic Fluid Tanks:

Micro 3.3 (0.72) JCB Hydraulic Oil HP32

Part No. 4002/1000
Compact III 4.0 (1.09) JCB Hydraulic Oil HP32
Part No. 4002/1000
Beaver III 7.0 (1.53) JCB Hydraulic Oil HP32
Part No. 4002/1000
Trojan III 7.0 (1.53) JCB Hydraulic Oil HP32
Part No. 4002/1000
Duopower III 7.0 (1.53) JCB Hydraulic Oil HP32
Part No. 4002/1000

9803/1250 Issue 1
E27 MAINTENANCE E27
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT
Beaver III, Compact III and Trojan III

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

The engine speed of the powerpack is controlled by a small

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

To enable these adjustments to be carried out the following

piece of test equipment is required:

Hydraulic Flow and Pressure Tester

(JCB Attachments Part number 5073)

Note: To gain access to the relief valve it is necessary to

move the tubular frame.

1 Connect the Test Equipment

Connect the hydraulic flow and pressure tester to the

machine as shown

2 Start the Engine

Start the engine (see Operation Section) and allow the

machine at least 5 minutes to warm up with the test
equipment adjusted to read approximately 55 bar (800
lbf/in2).

3 Check the Flow Rate

a Adjust the test equipment shut-off valve A until the

following pressure reading is registered on test
gauge B.

Compact III machines - 69 bar (1000 lbf/in2)

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

b Read off the flow rate as indicated on the flow

gauge C.

c If the correct flow rate is indicated go to Step 7, if

incorrect go to Step 4.

Note: The correct flow rates depend on the machine model

as below:

Category C models - 20 litres/min

Category D models - 30 litres/min
Category E models - 40 litres/min

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

Note: Overspeeding of tools could also invalidate the

warranty.

9803/1250 Issue 1
E28 MAINTENANCE
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued)
Beaver III, Compact III and Trojan III
(continued)
4 Check Relief Valve Setting
a Close off the shut-off valve A gradually until a
readying of no greater than the following is obtained:
Compact III machines - 86 bar (1250 lbf/in2)
Beaver III machines - 138 bar (2000 lbf/in2)
Trojan III machines - 138 bar (2000 lbf/in2)
b Remove the relief valve adjustment seal cap D.
c Loosen adjusting screw locking nut E.
! CAUTION
The pressure settings quoted above must not be
exceeded.
The pressure setting may now be adjusted by means of
adjusting screw F.
5 Re-check the Flow
a Readjust the shut-off valve A until the following
pressure reading is again registered on the test
gauge B.
Compact III machines - 69 bar (1000 lbf/in2)
Beaver III machines - 90 bar (1300 lbf/in2)
Trojan III machines - 138 bar (2000 lbf/in2)
9803/1250
E28
b Read off the flow rate on the flow gauge C.
Note: If the correct flow rate is not indicated go to Step 7. If
still incorrect go to Step 6.
6 Adjust the Flow Rate
a Loosen the nuts G on the throttle ram piston rod.
b Adjust the barrel nut H up to increase the engine
speed.
Note: The test gauge B must be continually checked and
the shut-off valve A adjusted to maintain the following
pressure during speed adjustment:
Compact III machines - 69 bar (1000 lbf/in2)
Beaver III machines - 90 bar (1300 lbf/in2)
Trojan III machines - 90 bar (1300 lbf/in2)
! CAUTION
Do not exceed the rated maximum of 20 litres/min, or 30
litres/min at 3600 rev/min (depending on model).
7 Check the Throttle Return
Open the shut-off valve A and ensure that the throttle
ram has fully returned into its cylinder by pushing the
end of the piston rod.
8 Carry out a Functional Check
Finally, check that the machine operates satisfactorily
by connecting and operating a tool.
Note: The illustration above shows that hydraulic ram as
mounted on petrol engine models. The ram is mounted
differently on diesel engine models but the adjustments are
are same.
Ensure that all controls and adjusters are fully secured and
that all covers are replaced when adjustments are
completed.
Issue 1
E29 MAINTENANCE E29
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued)
Duopower III

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

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

loaded.

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

Note: Overspeeding of tools could also invalidate the

warranty.

To enable these adjustment to be carried out the following

piece of test equipment is required:

Hydraulic Flow and Pressure Tester

(JCB Attachments Part Number 5073)

Note: To gain access to the relief valve it is necessary to

move the tubular frame.

1 Connect the Test Equipment

Connect the hydraulic flow and pressure tester to the

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

2 Start the Engine

Start the engine (see Operations Section) and set the

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

3 Check the Secondary Circuit Flow Rate

a Adjust the test equipment shut-off valve A until until

a pressure reading of 90 bar (1300 lbf/in2) is
registered on test gauge B.

b Read off the flow rate as indicated on the flow

gauge C. This should be 20 litres/min.

9803/1250 Issue 1
E30 MAINTENANCE E30
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued)
Duopower III (continued)

4 Check the Secondary Relief Valve Setting

a Gradually close shut-off valve A, the reading should

not exceed 138 bar (2000 lbf/in2).

b If the pressure is incorrect, remove the relief valve

adjustment screw seal cap D.

c Loosen adjusting screw lock nut E.

! WARNING
The pressure setting must not exceed 138 bar (2000
lbf/in2).

d Adjust the pressure setting using screw F.

5 Recheck the Flow

a Re-adjust the shut-off valve A until a pressure

reading of 90 bar (1300 lbf/in2) is again shown on
test gauge B.

b Read off the flow rate ad indicated on the flow

gauge C. This should be 20m litres/min.

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

Attachments Distributor.

6 Reconnect the Test Equipment

Stop the engine and connect the hydraulic flow and

pressure test equipment to the main hydraulic circuit
(upper set of couplings).

7 Start the Engine

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

8 Check the Main Circuit Flow Rate

a Adjust the test equipment shut-off valve A until a

pressure gauge reading of 90 bar (1300 lbf/in2) is
registered on test gauge B.

b Read off the flow rate as indicated on the flow

gauge C. This should be 20 litres/min.

9803/1250 Issue 1
E31 MAINTENANCE E31
HYDRAULIC POWER PACKS
HYDRAULIC CIRCUIT - ENGINE SPEED AND RELIEF VALVE ADJUSTMENT (continued)
Duopower III (continued)

9 Check the Main Relief Valve Setting

a Gradually close shut-off valve A, the reading should

not exceed 138 bar (2000 lbf/in2). If the pressure is
correct, go to paragraph 11.

b If the pressure is incorrect, remove the relief valve

adjustment screw seal cap D.

c Loosen adjusting screw lock nut E.

! WARNING
The pressure setting must not exceed 138 bar (2000
lbf/in2).

d Adjust the pressure setting by means of screw F.

10 Recheck the Flow

a Re-adjust the shut-off valve A until a pressure

reading of 90 bar 1300 lbf/in2) is again shown on
test gauge B.

b Read off the flow rate on flow gauge C. This should

be 20 litres/min. If the flow rate is now incorrect,
consult your JCB Dealer.

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

a Set the flow rate selector lever to 40 litres/min (fully

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

b Read off the flow rate as indicated on the flow

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

9803/1250 Issue 1
E32 MAINTENANCE E32
HYDRAULIC POWER PACKS
BATTERY
! WARNING ! WARNING
Battery electrolyte contains sulphuric acid. If can burn you if Set all switches to OFF before disconnecting and
it touches your skin or eyes. Wear safety glasses and handle connecting the batteries. When disconnecting the batteries,
the batteries carefully to prevent spillage. take off the negative (-) lead first. When reconnecting the
batteries fit the positive (+) lead first.

! WARNING
Keep metallic items (watches, rings, zippers, etc) away from
the battery terminals. Such items could short the terminals
and burn you..
! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the batteries. Keep the batteries
away from sparks and naked flames.
! WARNING
Recharge the batteries away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the batteries. When you have
installed the batteries in the machine, wait five minutes
before connecting them up.
! WARNING
Do not top up the battery with acid. The electrolyte could
boil out and burn you.

Checking the Electrolyte Level First Aid - Electrolyte

1 Prepare the Machine Eyes

Position the machine on level ground. Switch off the Flush with water for 15 minutes. Get medical help
engine and allow it to cool down. immediately.

2 Remove the Battery covers Skin

Unscrew and remove battery covers. Flush with water. remove affected clothing.

3 Check the Level If Swallowed

a Look at the level in each cell. The electrolyte should
be 6 mm (1/4in) above the plates.
b Top up if necessary with distilled or de-ionised
water.
Do not induce vomiting. Drink large quantities of water or
milk. then drink Milk of Magnesia, beaten egg or vegetable
oil

4 Refit the Battery Covers

Refit battery covers.

9803/1250 Issue 1
E33 MAINTENANCE E33
HYDRAULIC POWER PACKS
FAULT FINDING
! WARNING
Maintenance must be done only by suitably qualified and
competent persons.

Symptom Possible Fault Remedy

Engine does not start No fuel Fill tank

Fuel On/Off switch OFF Turn ON
Rotary switch OFF Turn ON
Low engine oil Replenish engine sump
Choke incorrectly set for engine Temperature If cold set fully ON. If warm set ON
Spark plug fouled or wet Clean plug
Loose or broken plug lead Refit or renew, check for spark at plug
Ignition fault Check

Poor powerpack Powerpack output incorrect Check powerpack output with flow and
performance pressure tester
Low relief valve setting Check calibration
Poor engine speed adjustment Check calibration
Sticking or damaged throttle ram Repair or replace
Damaged hoses or couplers Replace
Blocked suction strainer Remove and clean
Worn or damaged hydraulic pump Repair or replace
Relief valve worn Replace
Damaged ‘O’ rings on relief valve Renew ‘O’ rings, coat valve with grease
and refit.
Faulty tool Consult tool Handbook

Engine speed does not idle
when tool not operating
Broken ram return spring Fit new spring
High system back pressure caused Check system
by hoses over 8 m or damaged hoses
or couplers
Unit not fully warmed up Allow to warm up (operate tool(s)
continuously)

Tool runs hot Blocked cooler air intake Cleat intake

Poor powerpack ventilation Re-site powerpack
High back pressure Check system
Damage to cooler fan Check for blade damage
Low relief valve setting Reset or replace

Unable to connect hoses
or tools
Pressure lock in system Connect return line first, vent system
using control valve mid position, vent
pressure from hose by unscrewing
connector.
Connector damaged Replace connector

Oil foams out of breather Leak of air into suction circuit, Tighten fittings, check cooler for
tanks, cooler or pump damage.

9803/1250 Issue 1
F1 SPECIFICATION F1

CONTENTS

Static dimensions F2

Engine types and powerpack weights F2

Flow rates and hose length F3

New developments F4

9803/1250 Issue 1
F2 SPECIFICATION F2
STATIC DIMENSIONS

Compact III Beaver III Trojan III/Doupowe III Micro

Height (A) - 505 mm (19.9 in) 610 mm (24.0 in) 735 mm (28.9 in) 480 mm (18.9 in)

Width (B) - 495 mm (19.5 in) 530 mm (21.0 in) 590 mm (23.2 in) 434 mm (17.08 in)

Length (C) - 630 mm (24.8 in) 720 mm (28.0 in) 812 mm (32.0 in) 626 mm (24.64 in)

Weight - 50 kg (110 lb) 75 kg (165 lb) - Honda 99 kg (218 lb) 48.5 kg (107 lb)
99 kg (218 lb) - Lombardini

ENGINE TYPES AND POWERPACK WEIGHTS

Powerpack Model Fuel Starting Engine Performance

Compact III 929/20000 Petrol Recoil Honda CG160 5.3 HP (4 kW)

Beaver III 929/16400 Petrol Recoil Honda GX240 8 HP (6 kW)

929/16600 Petrol Recoil Suzuki V270 9 HP (6.7 kW)
929/16100 Diesel Recoil Yanmar L70E 7 HP 95.2 kW)
929/17200 Diesel Recoil Lombardini 15LD 6.7 Hp (4.9 kW)
929/18000 Diesel Electric Lombardini 15LD 6.7 HP (4.9 kW)

Trojan III 929/32200 Diesel Recoil Robin DY 35D 8 HP (6 kW)

929/32300 Diesel Electric Robin DY 35D 8 HP (6 kW)
929/32000 Petrol Recoil Honda GX340 11 Hp (8.2 kW)
929/32100 Petrol Electric Honda GX340 11 Hp (8.2 kW)
929/32400 Petrol Recoil Honda GX390 13 HP (9.7 kW)
929/32500 Petrol Electric Honda GX390 13 Hp (9.7 kW)
929/32600 Diesel Recoil Yanmar L100AE-D 10 HP (7.5 kW)
929/32700 Diesel Electric Yanmar L100AE-DE 10 HP (7.5 kW)

Duopower 929/32800 Petrol Recoil Briggs & Stratton Vanguard 18 HP (13.4 kW)
929/32900 Petrol Electric Briggs & Stratton Vanguard 18 HP (13.4 kW)

Micro 929/92200 Petrol Recoil Honda GX160 5.3 HP (4 kW)

9803/1250 Issue 1
F3 SPECIFICATION F3
FLOW RATES AND HOSE LENGTH

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

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

Model Flow Rate (litres/min) Max. Pressure (bar) E.H.T.M.A. Cat.

Micro 0 - 20 138 C

Compact III 0 - 20 69 C

Beaver III 0 - 20 138 C

Trojan III 0 - 20 138 C

0 - 30 138 D

Duopower III 0 -20/0 - 40 150 C/E

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

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

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

9803/1250 Issue 1
F4 SPECIFICATION F4
NEW DEVELOPMENTS

As part of their policy of continuing development JCB

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

You should always check the serial number of your

Powerpack and speak with your JCB Dealer of JCB
Attachments if in any doubt.

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

9803/1250 Issue 1
F5 SPECIFICATION F5
NEW DEVELOPMENTS (continued)

STOP

x2 START

STOP

START

1021

Beaver - Yanmar

Fig. 1

x2

1022

Beaver - Lombardini

x2

1023
Fig. 2
Beeaver & Compact - Honda
1

x2
2 3

Trojan - Honda

1034 STOP

x2 START

Fig. 2A

STOP

START

1025

Trojan - Yanmar

Duopower

1037
Micro

9803/1250 Issue 1
F6 SPECIFICATION F6
NEW DEVELOPMENTS (continued)

STOP

START
x2

1027
Beaver - Yanmar

STOP
x2

1028
Beaver - Lombardini

x2

102
Beeaver & Compact - Honda

x2

1031
Trojan - Honda

STOP

START
x2

1032

Trojan - Yanmar

Duopower

1038

Micro

Fig. 4

9803/1250 Issue 1
F7 SPECIFICATION F7
NEW DEVELOPMENTS (continued)

Fig. 5 Fig. 6

Fig. 7 Fig. 8

Fig. 9 Fig. 10

1036 1035

Fig. 10a Fig. 10b

Fig. 11 Fig. 12

9803/1250 Issue 1
F8 SPECIFICATION
NEW DEVELOPMENTS (continued)
Introduction
The following powerpacks are covered by this handbook:
Beaver III, Compact III, Trojan III, Duopower, Micro.
To operate the JCB range of powerpacks efficiently and
safely you must know the powerpack and have the skill to
use it. If you are a new operator, you should become trained
in the skills of using a powerpack before trying to work with
it.
It is assumed that personnel carrying out maintenance have
at least a sound knowledge of workshop practice, safety
procedures and general techniques associated with the
repair of hydraulic equipment.
it is expected that components will be thoroughly cleaned
and lubricated, where appropriate, also that any opened
hose connections will be blanked to prevent entry of dirt and
excessive loss of hydraulic fluid.
Serial numbers are stamped on a spacer plate between the
engine and the hydraulic tank or chassis on the Micro.
It is important to quote the serial number when making
repairs or ordering parts.
Safety Decals
Keep all decals clean and readable. Replace lost or
damaged decals.
Before Operating the Machine
z Check for Cleanliness.
z Check for Damage.
z Check for Leaks.
z Make sure the fuel filler cap is tightly closed.
z Check Hydraulic Oil Level.
z Ensure the machine is positioned safely.
z Ensure that all hydraulic couplings are fully
serviceable. Refer to Hydraulic Couplings.
z Ensure that any hydraulic tools you are planning to use
are compatible with the model of the machine you are
using.
z Check Engine Oil Level
z Check the Fuel
! Never refuel with the engine running.
Operating in Low Temperatures
z Use the Correct Viscosity Engine Oil
See Engine Manufacturer's Handbook.
z Keep the Battery at Full Charge
z Fill the Fuel Tank at the End of each Working Period
z Protect the Machine When not in Use
Note: If the machine is to be used continually at
temperatures below 0°C consult your JCB Dealer.
9803/1250
F8
Connecting Hoses (Figs. 1, 2)
a Stop the engine.
b Move the Output control to mid position or off position.
c Attach Return line.
d Attach Feed line.
Note: The connector is locked when the collar is turned
away from the ball.
e Start the engine and run the machine to fill up the
hydraulic circuit.
f Check the hydraulic oil level.
Hydraulic Output Control and Connectors
BEAVER III, COMPACT III AND TROJAN III (Fig. 1)
MICRO (Fig. 2a)
Hydraulic output control (1) is used to control the flow rate to
the tool in use.
Connectors (2) and (3) are used to connect the powerpack
to the tool as follows:
Connector (2) - Feed (male).
Connector (3) - Return (female).
DUOPOWER III (Fig. 2)
Hydraulic output control (1) is used to control the flow rate to
the tool connected to the top couplings (4) and (5). This
(main) output can be 0-20 litres/min or 0-40 litres/min
depending on the position of flow rate selector control (3).
Hydraulic output control (2) is used to control the flow rate to
the tool connected to the lower couplings (6) and (7). This
(secondary) output is 0-20 litres/min. When in the left-hand
position, flow rate selector control (3) selects 0-20 litres/min
from both sets of couplings. When in the right-hand position,
the control selects 0-40 litres/min from the upper set of
couplings. Connectors (4) to (7) are used to connect the
main and secondary circuits to the tool in use as follows:
Connector (4) - Main circuit feed (male)
Connector (5) - Main circuit return (female)
Connector (6) - Secondary circuit return
(female)
Connector (7) - Secondary circuit feed (male)
Starting/Stopping (Figs. 3/4)
Notes:
Honda GX160, GX240, GX340 and GX390 Engines: The
engines are fitted with an Oil Alert system which is designed
to prevent engine damage caused by an insufficient amount
of oil in the crankcase. The oil alert system will automatically
shut down the engine before the oil in the crankcase can fall
below a safe limit.
If the Oil Alert system has shut down the engine then the Oil
Alert indicator will flash when you attempt to restart the
engine.
Yanmar L70E and L100E Engines: In cold weather if your
engine is hard to start, remove rubber plug and add 2 c.c. of
engine oil before starting (Fig. 5).
After starting, allow the engine to idle for a few minutes
then slacken the engine speed control (Fig. 6).
Lombardini 15LD315 Engines: After starting, allow the
engine to idle for a few minutes then slacken wingnut
(Fig. 7).
Issue 1
F9 SPECIFICATION F9
NEW DEVELOPMENTS (continued)

Starting/Stopping (Figs. 3/4) (continued) z Engine oil filter.

Temperature Idling Time Change
below -20°C 5 minutes z Engine oil
-20°C to -10°C 2 minutes z Hydraulic filter
-10°C to 5°C 1 minute
z Hydraulic oil
above 5°C 20 seconds

Recoil Start Models: Do not allow the starter grip to snap Every 100 hours or 6 Months
back against the engine. Return it gently to prevent damage. Do the Daily and 3-monthly jobs plus:
Check:
Lombardini Recoil Start Models: Pull the starter grip lightly z Tightness of nuts, bolts, screws and hose fittings.
until resistance is felt, then pull briskly.
z Flow and pressure output.
Yanmar Recoil Start Models: Use the starter grip to turn the
engine over until compression is reached, then push down Change
the compressor control B (Fig. 12).
z Main hydraulic filter.
Electric Start Models: Do not use the electric starter for more z Hydraulic fluid.
than 5 seconds at a time. If the engine fails to start, release
the key and wait 10 seconds before operating the starter z Engine oil. (See Engine Manufacturer's
again. Handbook).

Clean
Service Schedules z Fuel strainer.
z Spark plug - Petrol models only.
Apart from the daily jobs, the schedules are based on
machine running hours. Keep a regular check of hours in Check
use. Do not use a machine which is due for a regular service.
z Spark plug gap - Petrol models only.
Rectify any defects found during regular maintenance before
clearing the machine for use. Note: For detailed maintenance procedure, refer to Engine
Manufacturer's Handbook.
! WARNING Checking the Hydraulic Fluid Level (Fig. 8, 10a)
Maintenance must be done only by suitably qualified and
competent persons. Before doing any maintenance, 1 Prepare the Machine
make sure the machine is safe and correctly sited on Position the machine on level ground. Switch off the
level ground. engine and allow it to cool down.
2 Check the Hydraulic Fluid Level
Daily a Check the hydraulic fluid level using sight gauge A.
z Clean machine generally. Clean the machine using b If necessary top up the hydraulic fluid through filler
B.
water and/or steam. Do not allow mud to build up on
the engine. Make sure that the air inlets on the hydraulic Note: Use only the recommended hydraulic fluid.
cooler are not clogged.
Changing the Hydraulic Fluid (Fig. 8)
Check
z Generally for damage.
Note: The illustration shown is for a typical machine.
z Hydraulic fluid level.
z Engine oil level.
1 Position the machine on level ground. Switch off the
z Hydraulic couplings.
engine and allow it to cool down.
z Hydraulic hoses. 2 Drain the Hydraulic Fluid
Note: Check tightness of nuts, bolts, screws and hose a Place a container of a suitable size below the tank
fittings after the first days operation and thereafter in drain plug C to catch the fluid (Beaver, Compact,
accordance with Service Schedules. Trojan 2, Duopower only).
b Remove drain plug C and filler cap B and allow fluid
Note: The engine oil should be replaced after the first three to drain out.
days operation and thereafter in accordance with the 3 Replace the Hydraulic Fluid.
Maintenance Schedules. a Clean and refit drain plug C.
Every 50 hours or 3 Months b Pour fluid through filler until it reaches the required
Do the Daily jobs plus: level on sight gauge A.
Clean c Refit filler cap B.
z Air cleaner elements. Note: Use only the recommended hydraulic fluid.
(See Engine Manufacturer's Handbook).

9803/1250 Issue 1
F10 SPECIFICATION F10
NEW DEVELOPMENTS (continued)

Changing the Main Hydraulic Filter (Beaver, 2 Lift the tubular frame out of the way of the machine
Compact, Trojan2, Duopower ) components by hinging it on bolts B.
(Figs. 9/10) Note: It is important that after maintenance, the
tubular frame is restored to its operating position and
! WARNING that the clips A are securely fitted.
Hot oil and engine components can burn you. Make sure Note: When the machine is to be lifted using the
the engine is cool before doing this job. balanced lifting point C, it is important to ensure that
the clips A are in place and securely fitted.
! WARNING
There may be limited fluid spillage when the filter is
Checking the Electrolyte Level
removed. Clean any spillage immediately and dispose of
materials in accordance with current regulations.
1 Position the machine on level ground. Switch off the
engine and allow it to cool down.
Note: On Duopower III powerpacks, the hydraulic filter is
2 Unscrew and remove battery covers.
mounted on top of the hydraulic tank. 3 Look at the level in each cell. The electrolyte should be
6 mm (1/4 in.) above the plates.
4 Top up if necessary with distilled or de-ionised water.
1 Position the machine on level ground. Switch off the
5 Refit battery covers.
engine and allow it to cool down.
2 Place a container of suitable size beneath the filter to
catch any spilt fluid. ! WARNING
3 Remove the three bolts A securing the lid to hydraulic Battery electrolyte contain sulphuric acid. It can burn
filter housing B, and remove the lid. you if it touches your skin or eyes. Wear safety glasses
4 Lift out and dispose of the used filter. and handle the battery carefully to prevent spillage.
5 Push the new element C firmly into place in the filter
housing B.
6 Refit the lid on the filter housing B, ensuring that spring
clip D locates between spigots E. Secure with the three
bolts A.
7 Check the hydraulic fluid level, see Checking the
Hydraulic Fluid Level.

(Micro)
(Fig. 10b)

1 Position the machine on level ground. Switch off the

engine and allow it to cool down.
2 Place a container of suitable size beneath the filter to
catch any spilt fluid.
3 Remove oil filter canister with oil filter wrench or hand.
4 Replace with a new oil filter canister.
5 Check the hydraulic fluid level, see Checking the
Hydraulic Fluid Level.

Cleaning the Cooler

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

Gaining Access to Machine Components (Fig. 11)

To facilitate easier maintenance, the tubular frame is fitted

with hinge bolts. The frame may be moved to afford ready
access to the machine components in the following manner:

1 Remove and retain securing clips A.

Note: Access to Micro is achieved by removing the four bolts

in the tubular frame.

9803/1250 Issue 1
F11 SPECIFICATION F11
NEW DEVELOPMENTS (continued)

Average Noise Levels (Lpa)

Model Engine at 1 metre at 4 metres at 7 metres

Micro Honda GX160 89.4 dB(A) 81.7 dB(A) 77.6 dB(A)

Compact III Honda GX160 92.9 dB(A) 85.5 dB(A) 81.6 dB(A)
Beaver III Honda GX240 88.6 dB(A) 82.8 dB(A) 79.2 dB(A)
Suzuki V270 90.8 dB(A) 84.1 dB(A) 79.7 dB(A)
YanmarL70E 91.7 dB(A) 85.9 dB(A) 81.4 dB(A)
Lombardini 15LD 93.9 dB(A) 88.0 dB(A) 82.8 dB(A)
Trojan III Honda GX340 92.9 dB(A) 85.5 dB(A) 81.6 dB(A)
Honda GX390 93.4 dB(A) 86.8 dB(A) 82.1 dB(A)
Robin DY 35D 96.6 dB(A) 90.5 dB(A) 85.9 dB(A)
Yanmar L100E 97.6 dB(A) 88.8 dB(A) 75.9 dB(A)
Duopower III Briggs & Stratton
Vanguard 94.6 dB(A) 85.5 dB(A) 82.0 dB(A)

Fluids & Capacities

ITEM CAPACITY FLUID/LUBRICANT

Litres (Gal)
Engine (Oil) Refer to Manufacturer's Refer to Manufacturer's
Handbook as supplied. Handbook as supplied.

Fuel Tanks:
Honda GX160 3.6 (0.79) Unleaded petrol
Honda GX240, GX340, GX390 6.0 (1.32) Unleaded petrol
Yanmar L70E 3.5 (0.77) Refer to Manufacturer's Handbook
Yanmar L100E 5.5 (1.45) Refer to Manufacturer's Handbook
Lombardini 15LD 4.3 (0.95) Refer to Manufacturer's Handbook
Briggs & Stratton Vanguard 8.5 (1.87) Refer to Manufacturer's Handbook

Hydraulic Fluid Tanks:

Micro 3.3 (0.72)

Compact III 4.0 (1.09) JCB Hydraulic Oil HP 32 -
Beaver III 7.0 (1.53) Part No. 4002/1000
Trojan III 7.0 (1.53)
Duopower III 7.0 (1.53)

9803/1250 Issue 1
JCB ATTACHMENTS

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

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

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

WARRANTY POLICY
This JCB Attachments is guaranteed against defects in workmanship and/or material when properly maintained and
operated under conditions laid down in the WARRANTY AND PROCEDURE.

Should any defect develop in the unit during the warranty period you are advised to contact your JCB Dealer. In the event of
the fault being attributed to bad workmanship or defective manufacture or material, the dealer will take the appropriate
warranty action. (The Manufacturer’s Warranty does not apply to proprietary or other components not of its manufacture
used with the equipment.)

For conditions of warranty, please see overleaf.

 WARRANTY AND PROCEDURE

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

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

a e
The Manufacturer’s liability extends In the event of the rejection by the
only to repair or replacement and it Manufacturer of any claim, the part or
accepts no liability for any parts returned will be destroyed
consequential or other loss, damage unless specific instructions to the
or injury resulting directly or indirectly contrary were given when the part or
from any defect in the goods. parts were returned.
h
This warranty should be construed as
strictly limited in its application to new
JCB Products and if the goods shall
change hands during the period of
this warranty shall cease to have any
effect.

b f i
The Manufacturer’s warranty does not The registration card must be The Manufacturer accepts no
extend to failures, defects or damage returned to the Manufacturer within responsibility for damage by fires or
attributable to wear and tear, seven days of the receipt of any new accident of any kind to any goods
improper adjustment, neglect, Attachment. returned to it under the terms of this
alteration of specification, or accident. warranty nor does the Manufacturer
g accept responsibility for any accident
c No claim will be considered if other occurring to such goods whilst on the
Defective parts must be returned to than genuine parts manufactured by premises.
the Main Dealer when requested the Manufacturer or to its order and
together with full particulars of the listed in its catalogue are used or if j
defects, the serial number, the hours other than JCB ‘Special’ Hydraulic This warranty shall cease to have
worked and the date the unit was Fluid is used where specified. effect if the Purchaser removes or
supplied to the Main Dealer who will defaces or alters the Manufacturer’s
claim on your behalf. Number or Name Plates or any other
numbers or marks affixed to any JCB
d Product.
The Manufacturer’s warranty does not
extend to proprietary or other k
components not of its manufacture, In respect of machines sold which
but will as far as possible pass to the have been used since the date of
Purchaser the benefits of any manufacture by the Manufacturer for
guarantee given to the Manufacturer demonstration purposes the term of
in respect of such components. this warranty shall be three months.
EQUIPMENT REGISTRATION CARD/CARTE DÕENREGISTREMENT-DÕEQUIPEMENT/
GER€TE-GARANTIEKARTE/GARANTIEKAART/SCHEDA DI REGISTRAZIONE PER
ATTREZZATURE
For the Warranty to become effective the self-addressed card below must be completed and returned within 14 days of retail
purchase.
Pour que la garantie soit valide, il est impératif que la fiche ci-dessous nous soit renvoyée à l'adresse indiquée sur celle-ci, et
ce dans un délai de 14 jours à compter de la date de l'achat au détail.
Um die Garantie wirksam zu machen, muß die untenstehende adressierte Karte innerhalb von 14 Tagen nach dem Kauf
ausgefüllt und eingesandt werden.
Para la Garantía sea efectiva, por favor rellene la tarjeta adjunta y remitanosla dentro de los 14 días siguientes a la fecha de
compra.
Om de garantie van kracht te laten worden moet de antwoordkaart hieronder binnen 14 dagen na aankoop van het product
ingevuld worden geretourneerd.
Per attivare la garanzia compilare la scheda con indirizzo prestampato e restituirla entro 14 giorni dall'acquisto.
Warranty Department, JCB ATTACHMENTS Riverside, Rugeley, Staffordshire, England, WS15 2WA
FOR YOUR RECORD/POUR VOS ARCHIVES/FÜR IHRE AKTEN/PARA SU REGISTRO/VOOR UW ARCHIEF/
PER I VOSTRIARCHIVI

EQUIPMENT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPE D’EQUIPEMENT/GERÄT/TIPO DE EQUIPO/
UITRUSTING TYPE/TIPO DI ATTREZZATURA

SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No DE SERIE/SERIENNUMMER/No DE SERIE/
SERIENR./NUMERO DI SERIE

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

PURCHASED FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACHETE CHEZ/GEKAUFT VON/COMPRADO DE/
GEKOCHT BIJ/ACQUISTATA PRESSO

JCB ATTACHMENTS
EQUIPMENT REGISTRATION CARD/CARTE D’ENREGISTREMENT - D’EQUIPEMENT/
TARJETA DE REGISTRO DE EQUIPOS/GERÄTE-GARANTIEKARTE/
GARANTIEKAART/SCHEDA DI REGISTRAZIONE PER ATTREZZATURE

EQUIPMENT TYPE
TYPE D’EQUIPEMENT/GERÄT/TIPO DE EQUIPO
UITRUSTING TYPE/TIPO DI ATTREZZATURA

Serial No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No de Série:/Seriennummer/No de Serie:
Serienr.:/N. di Serie:

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

Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adresse:/Anschrift/Dirección:
Adres:/Indirizzo:

Date received: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date reçu:/Lieferdatum/Fecha de recepción:
Datum van ontvangst:/Data di ricezione:

Your Company Name: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nom de votre Firme:/Ihre Firmenbezeichnung/Nombre de la
Empresa:/Uw firmanaam:/Nominativo della vostra ditta

Address:/Adresse:/Anschrift:/Dirección/Adres:/Indirizzo: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...............................................................................................
...............................................................................................

Tel. No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. de téléphone:/Telefonnummer:/No. Teléfono/Tel. Nr./Tel. N.

E/F/G/S/Du/L 9804/7133 Iss. 5

JCB ATTACHMENTS

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