JCB HM012T, HM018T, HM026T, HM033T, HM049T, HM054T, HM080T, HM090T, HM120T, HM160T, HM180T, HM200T, HM270T, HM380T Large Hydraulic Breakers O1 PDF

JCB LARGE HYDRAULIC BREAKERS
OPERATOR MANUAL
HYDRAULIC BREAKERS (HM SERIES)
JCB Attachments
Waterloo Park
Uttoxeter
Staffordshire, ST14 5PA
England
This manual contains original instructions verified by the manufacturer (or their authorized
representative).
Important: This manual should always stay with machine
Publication No.
333/A9900-3
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
0 333/A9900-3 0
Contents
Contents Page No.

Introduction
About this Manual .......................................................................................... 1
Units of Measurement .............................................................................. 1
Intended use ............................................................................................. 1
Special conditions of use .......................................................................... 1
Carrier Machine Suitability ....................................................................... 1
Machine stability ....................................................................................... 1
Setup ........................................................................................................ 1
General Description ....................................................................................... 2
Check List - Equipment ............................................................................ 2
Safety ............................................................................................................ 4
Safety - Yours and Others ........................................................................ 4
Safety Warnings ....................................................................................... 4
Safety Check List ..................................................................................... 5
Safety Labels ................................................................................................. 8
Safety Label Identification ........................................................................ 8
Installation and Removal

Safety .......................................................................................................... 11
Safety First ............................................................................................. 11
Hanger Bracket ............................................................................................ 12
Installation ................................................................................................... 13
Installing to JCB Robot (Skid Steer Loader) ........................................... 15
Removal ...................................................................................................... 16
Non JCB Carriers ................................................................................... 17
Tools ............................................................................................................ 18
HM012T - HM049T ................................................................................. 18
HM080T - HM380T ................................................................................. 19
Storage ........................................................................................................ 21
Operation
General Safety ............................................................................................ 23
Safety First ............................................................................................. 23
Start and Stop the Hammermaster ......................................................... 23
Principles of Breaking ............................................................................. 23
Tool .............................................................................................................. 24
Selection of the Right Tool ...................................................................... 24
Standard Tools ........................................................................................ 24
Breaking - Do's and Don'ts .......................................................................... 25
Point to Remember ................................................................................ 25
Do ........................................................................................................... 25
Don't ....................................................................................................... 27
Noise Dampening ................................................................................... 28
Preparation .................................................................................................. 30
Seat Position .......................................................................................... 30
Adjuster valve to control impact blows ................................................... 31
The Effects of Blank Firing .......................................................................... 32
To prevent blank firing: ........................................................................... 32
Travelling with the Hammermaster .............................................................. 33
On Site ................................................................................................... 33
On a Truck .............................................................................................. 33
i i
Contents
Contents Page No.

Hydraulic Oils, Filtering and Cooling ........................................................... 34
Introduction ............................................................................................. 34
Possible Result of using incorrect Oil ..................................................... 34
Special Oils ............................................................................................. 34
Hydraulic Oil Purity ................................................................................. 34
Oil Filter .................................................................................................. 35
Maintenance
Health and Safety ........................................................................................ 37
Safety First ............................................................................................. 37
Lubricants ............................................................................................... 37
Service Requirements ................................................................................. 38
Main Inspection ...................................................................................... 38
Obtaining Replacement Parts ................................................................. 38
Service Schedules ....................................................................................... 39
Grease .................................................................................................... 39
Every 2 - 4 Hours (Depending on operating conditions) ........................ 40
Daily ....................................................................................................... 41
Weekly .................................................................................................... 41
Every 500 Hours or Yearly (whichever occurs first) ................................ 42
Checking the low pressure accumulator ................................................ 43
Checking the high pressure accumulator ............................................... 45
Conversion table for charging N2-gas pressure to back head ............... 49
Lower Tool Bushing and Tools ..................................................................... 50
Checking For Excessive Wear ............................................................... 50
Check for and Removal of Burrs ............................................................ 50
Wear Limits and Tool for Lower Tool Bushing ............................................. 51
Tool Retention Pin Wear Limits .............................................................. 51
Tool Wear Limits ..................................................................................... 51
Upper Dampener Wear Limits ................................................................ 52
Lower Dampener Wear Limits ................................................................ 52
Upper Bush Wear Limits ......................................................................... 53
Bottom Bush Wear Limits ....................................................................... 53
Retainer Pin Wear Limits ........................................................................ 54
Housing Pad Wear Limits ....................................................................... 55
Automatic Greasing System ........................................................................ 56
Disposal of Consumable .............................................................................. 57
End of Life Disposal ............................................................................... 57
Specification
Machine Specification .................................................................................. 59
Torque Settings ........................................................................................... 61
BSP Hose Connection ............................................................................ 61
Code 62 SAE Flange Coupling .............................................................. 61
Service
Fault Finding ................................................................................................ 63
Part Numbers
Breaker Models ........................................................................................... 69
Nitrogen Adaptor Reference Chart .............................................................. 71
Hose Assesories .......................................................................................... 74
Male Fitting ............................................................................................. 74
ii ii
Contents
Contents Page No.
iii iii
Introduction
About this Manual
Introduction
About this Manual
This document details the relevant use and maintenance Important: The breaker as a standard assembly must not
procedures for the JCB Hammermaster. The safety be used under water. If water fills the space where the
information included is directly relevant to operation and piston strikes the tool, a strong pressure wave is generated
maintenance of the Hammermaster. General safety and the breaker will be damaged.
information, and that relevant to the carrier machine is not
included. For details about safe operation of the carrier Carrier Machine Suitability
machine, see the relevant documents.
The Hammermaster is suitable for use with the JCB JS
Important: Do not attempt to install, operate or maintain Excavator which falls within the Hammermasters `carrier
any attachment until you have read and understood all weight' of 1T-50T tonne when fitted with a high flow
relevant operator documentation for both the attachment, auxiliary/Breaker hydraulic circuit. An installation kit,
and the carrier machine. Pay particular attention to safety suitable hanger bracket and a hose kit are available from
information. You must observe all relevant laws and your JCB Distributor.
regulations.
The Hammermaster is suitable for use with some other
The manufacturer's policy is one of continuous non JCB carrier machines. See the specification section
improvement. The right to change the specification of the for details of typical carrier requirements. Contact your
machine without notice is reserved. No responsibility will JCB Distributor for advice.
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
Machine stability
contained in this publication.
The breakers centre of gravity is considerably further away
Units of Measurement from the excavators pivot than other attachments such as
a bucket. The stability chart in the excavator cab applies
In this manual, the S.I. system of units is used. For only to a direct vertical load on the dipper end. If the
example, liquid capacities are given in litres. The Imperial breaker is used at full reach in a near horizontal position a
units follow in parenthesis (), for example 28 litres (6 UK larger capacity machine will be required to maintain
gal). stability.
Intended use If a quick hitch is used this adds additional weight to the
excavator dipper end an moves the centre of gravity of the
For fitment to tracked or wheeled slew type excavators for breaker further away increasing instability.
the breaking of rock shale, concrete by impact. Not for use
as a lifting devise or levering Setup
Special conditions of use Get your JCB dealer to set up the breaker on the carrier
machine. The correct flow is set by engine speed and the
If the breaker is to be used in conditions that differ from maximum pressure is set by the Auxiliary Releif Valve
normal breaking or demolition work conditions, such as Some machines have two auxiliaries relief valves, be sure
to under stand the purpose of both.
– tunnel application,
– foundry cleaning,
– underwater operations,
– underwater operations,
– use of special hydraulic oils,
– other special conditions, it may require modifications
to attachment, special operating techniques,
increased maintenance or special wear items.
In case of use in special conditions, contact your JCB

dealer
1 333/A9900-3 1
Introduction
General Description
General Description
Check List - Equipment

The Hammermaster is supplied as follows:
1 Breaker - assembled with mounting side plates.
2 Tail Hoses.
3 Moil Tool.
4 Grease Gun.
5 JCB Extreme Hammer Grease Cartridge. HM 012T - HM 018T
6 Noise Warning Decal (self adhesive). A
7 Operator Handbook. B
C
Attachment Identification
D
Serial Number - Always quote the serial number given on
E
the breaker's rating plate when obtaining replacement
parts. The rating plate is usually located on the left hand
side plate of the hammer. K Fig 1. ( T 2). F
P046850-02
Fig 1.
N
Component Identification P046850-01
Fig 2.
Key Components
A Housing
B Hanger Bracket
C Hydraulic Connections
D Tool
E Control Valve (behind plate)
F Accumulator (behind plate)
G Lifting Point
2 333/A9900-3 2
Introduction
General Description
Lifting
!MWARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2
Place chains or slings to lift the breaker. K Fig 3. ( T 3).
To stabilise the lift additional straps can be used with

suitable lifting eye /lug on the mounting flange or through
the dipper pivots.
Note: Do not lift using tool.
P046730-03
Fig 3.
3 333/A9900-3 3
Introduction
Safety
Safety
Safety - Yours and Others Safety Warnings

INT-1-3-1_3
All machinery can be hazardous. When a machine is

This safety alert system identifies
correctly operated and properly maintained, it is a safe
important safety messages in this
machine to work with. But when it is carelessly operated or
manual. When you see this symbol, be
poorly maintained it can become a danger to you (the
alert, your safety is involved, carefully
operator) and others.
read the message that follows, and inform
other operators.
In this manual 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 fully In this publication and on the machine, there are safety
understand the warning messages, ask your employer or notices. Each notice starts with a signal word. The signal
JCB distributor to explain them. word meanings are given below.
But safety is not just a matter of responding to the !MDANGER

warnings. All the time you are working on or with the
machine you must be thinking what hazards there might be Denotes an extreme hazard exists. If proper
and how to avoid them. precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
Do not work with the machine until you are sure that you injured.
can control it. INT-1-2-1
Do not start any job until you are sure that you and those
around you will be safe.
!MWARNING
Denotes a hazard exists. If proper precautions are not
If you are unsure of anything, about the machine or the job, taken, the operator (or others) could be killed or
ask someone who knows. Do not assume anything. seriously injured.
INT-1-2-2
Remember
BE CAREFUL
!MCAUTION
Denotes a reminder of safety practices. Failure to
BE ALERT
follow these safety practices could result in injury to
BE SAFE the operator (or others) and possible damage to the
machine.
INT-1-2-3
4 333/A9900-3 4
Introduction
Safety
Safety Check List Safety labels are strategically placed around the machine
to remind you of possible hazards.
!MWARNING If you need eye-glasses for reading, make sure you wear
Equipment Condition them when reading the safety labels. Do not over-stretch
Defective equipment can injure you or others. Do not or place yourself in dangerous positions to read the safety
operate equipment which is defective or has missing labels. If you do not understand the hazard shown on the
parts. safety label, then refer to Safety Label Identification.
Make sure the maintenance procedures in this manual Note: The illustration(s) show a typical machine model.
are completed before using the equipment. Your machine may look different from the model shown.
A-1-4-1
Keep all safety labels clean and readable. Replace lost or
damaged safety labels. Make sure replacement parts
!MWARNING include safety labels where necessary. Each safety label
Modifications and Welding has a part number printed on it, use this number to order a
The accumulator(s) in the Hammermaster are new safety label from your JCB distributor.
pressurised even when there is no hydraulic pressure
to the breaker. Never tamper with an accumulator. !MWARNING
Attempting to dismantle an accumulator without first
releasing the pressure can cause injury or death. Such Manual
work should only be carried out by qualified servicing You and others can be injured if you operate or
personnel who have studied the relevant Service maintain the attachment or equipment without first
Manual. studying this manual. Read the safety instructions
before operating the attachment or equipment. If you
B-1-3-7
do not understand anything, ask your employer or
JCB Dealer to explain it. Keep this manual clean and in
!MWARNING good condition.
Modifications and Welding A-1-3-2_1
Non-approved modifications can cause injury and
damage. Contact your JCB dealer for advice before !MCAUTION
modifying the equipment. Before welding on the
Hammermaster while it is installed on the carrier, Regulations
disconnect the carrier alternator and battery. Note that Obey all laws, work site and local regulations which
electric welding of the Hammermaster tools will render affect you and your machine.
them useless and make the warranty void. INT-1-3-3
B-1-3-2_1
!MWARNING
!MCAUTION Care and Alertness
Protect your ears. Working with the Hammermaster All the time you are working with or on the machine,
without wearing earmuffs can damage your hearing. take care and stay alert. Always be careful. Always be
Wear earmuffs when working with the hammer. alert for hazards.
INT-1-3-5
B-2-1-13
!MWARNING
Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.
INT-1-3-11
5 333/A9900-3 5
Introduction
Safety
!MWARNING !MWARNING
Practise Prolonged running can cause hydraulic components
You or others can be killed or seriously injured if you to heat up. Skin contact with these components must
do unfamiliar operations without first practising them. be avoided.
Practise away from the work site on a clear area. Keep B-1-2-18
other people away. Do not perform new operations
until you are sure you can do them safely.
INT-2-1-1
!MCAUTION
Every breaker has its own flow requirement. If the
!MWARNING machine is not preset to deliver the correct flow for the
breaker fitted, either the breaker will not function
Communications correctly or the machine may be damaged.
Bad communications can cause accidents. Keep
people around you informed of what you will be doing. Whenever a breaker is fitted, it is ESSENTIAL that the
If you will be working with other people, make sure any engine speed is correctly preset to suit the breaker.
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on Have your JCB dealer reset the engine speed before
spoken commands. using the machine with a new breaker fitted. This is a
INT-2-2-3 specialist job and the machine can be seriously
damaged if it is not done correctly.
!MWARNING ATT026
Repairs
If your machine does not function correctly in any way,
!MWARNING
get it repaired straight away. Neglect of necessary Metal Splinters
repairs could result in an accident or affect your You can be injured by flying metal splinters when
health. Do not try to do repairs or any other type of driving metal pins in or out. Use a soft faced hammer
maintenance work you do not understand. To avoid or copper pin to remove and fit metal pins. Always
injury and/or damage get the work done by a specialist wear safety glasses.
engineer. INT-3-1-3_2
GEN-1-5_2
!MCAUTION
!MWARNING Take care when lifting/handling. Refer to
Fluid Under Pressure SPECIFICATION for the attachment weight.
Fine jets of fluid at high pressure can penetrate the B-2-1-2_2
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
!MCAUTION
and then inspect the cardboard for signs of fluid. If Equipment Condition
fluid penetrates your skin, get medical help Operating the equipment beyond its design limits can
immediately. cause damage. It can also be dangerous
INT-3-1-10_3
Do not operate the equipment outside its limits.
!MWARNING Do not try to upgrade the equipment's performance by
Hydraulic fluid at pressure can injure you. Make the unapproved modifications.
machine safe before connecting/disconnecting the A-1-4-2
hoses. To do this stop the engine and then, with the
starter switch 'ON', operate the carrier auxiliary circuit
controls a few times to vent system pressure.
B-1-3-5
6 333/A9900-3 6
Introduction
Safety
!MWARNING
If two people are doing this job make sure that the
person working the controls is a competent operator.
If the wrong control lever is moved, or if the controls
are moved violently, the other person could be killed
or injured.
B-2-1-8
!MWARNING
Hydraulic oil at pressure can injure you. Make the
machine safe as detailed below before removing the
hose blanking plug. Follow the instructions below for
connecting the hoses.
8-4-1-3
!MWARNING
Before doing any routine maintenance work on the
attachment while it is installed on a carrier, make the
carrier safe. Stop the engine and, if appropriate,
ensure that the parking brake is engaged and the drive
is in neutral. Remove the starter key to prevent the
engine being started.
ATT008
!MWARNING
When using an attachment for example a hydraulic
breaker, where the risk of flying debris is present, a
protective layer or screen guard must be attached to
the front of the cab to protect the operator from flying
debris which could cause injury.
8-5-1-5
!MWARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a 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. Remove rings, watches and personal
jewellery.
INT-1-3-6_2
7 333/A9900-3 7
Introduction
Safety Labels
Safety Labels
Safety Label Identification

The following labels are installed to the Hydraulic Breaker.
332/P7131-1
817/70014-3
P046730-02
Fig 4.
Note: The annotation on each label refer to the machine

illustration and show their position on the machine. The
above picture can be used as a reference for label
positioning on any of the JCB large breaker models.
8 333/A9900-3 8
Introduction
Safety Labels
Part Numbers and Description
1. ISO-15B 5. ISO-01A
Part number: 817/70132 Part number: 817/70014
Description: Flying Debris. Description: Warning. Read the
operator manual before you
operate the machine.
2. ISO-06A 6. Label-Sound Power

Part number: 332/F5855
Description: Risk of Explosion.
Description: The label states the
guaranteed sound power level in
accordance with EC directive
2000/14/EC.
3. Label-N2 7. Label-Grease Point

Part number: 332/A2936 Part number:817/20178
Description: Use only nitrogen gas to Description: If autogrease system
charge accumulator(s). fails, manual lubrication is
P030080-5
required. Label indicates the
location of the filling valve.
4. ISO-15C
Part number:332/P4712
Description: Warning. Noise hazard. Ear
protection must be worn.
9 333/A9900-3 9
Introduction
Safety Labels
Page left intentionally blank
10 333/A9900-3 10
Safety

Safety
Safety First
Before you install/remove the tool carefully read the
following:
1 Tool might move unexpected inside the breaker.
2 Tool and breaker may have sharp edges. Wear safety

gloves when handling the working tool.
3 Working tool is heavy and might be hot. Wait until tool

cools and use lifting equipment, The carrier must be
switched off before performing the following work.
Always follow the working tool installation and

maintenance instructions to prevent the detachment
of the tool.
Note: The illustration shows a typical Hammermaster and

a typical JCB JS Series machine. The following
instructions assume that the bucket has already been
removed - refer to the carrier Operator Handbook.
!MWARNING
Controls
You or others can be killed or seriously injured if you
operate the control levers from outside the machine.
Operate the control levers only when you are correctly
seated.
0179_2
11 333/A9900-3 11
Hanger Bracket
Hanger Bracket
!MWARNING Breaker models including and over HM080T use Allen

screws with a nordlock washer. K Fig 1. ( T 12).
Always use appropriate hanger bracket for the breaker
and the carrier.
ATT027
!MWARNING
Use only appropriate fasteners to attach the hanger
bracket to the breaker.
ATT028
Lay the hydraulic breaker on squared beams or a pallet

within reach of the excavator boom with the service
window of the breaker housing facing upwards.
Insert the elastic pad in the breaker box, ensuring it is the

right way round, and fix the hanger bracket to the breaker
housing with two screws and Nordlock washers.
Hangers are attached to the boxed versions with bolts

sizes and torque settings. K Table 1. ( T 12).
Table 1.
Model Bolt Size Torque Nm P046850-03
Fig 1.
HM012T M16 200
A Screw
HM018T M18 250
B Elastic Pad
HM026T M18 250
C Hanger Bracket
HM033T M18 250
D Nordlock Washer
HM049T M18 250
HM054T M18 250
HM080T M24 690
HM090T M24 690
HM120T M24 690
HM160T M24 690
HM180T M24 690
HM200T M24 690
HM270T M36 2400
HM380T M36 2400
For boxed versions of breaker models HM012T to

HM054T attachement of the breaker to the hanger bracket
is with nuts and bolts
12 333/A9900-3 12
Installation
Installation
N P
A
B
F
P046730-44
Fig 2.
Note: If the breaker is being installed for the first time the
machine will require setting up, this will be done by your
!MWARNING
JCB Dealer. If two people are doing this job make sure that the
person working the controls is a competent operator.
Note: This job is easier done by two people - one to If the wrong control lever is moved, or if the controls
operate the controls and one to line up the pivots.The are moved violently, the other person could be killed
assistant should be in clear view of the operator at all times or injured.
B-2-1-8
1 Position the Hammermaster
During breaker mounting, the carrier should only be
Set the breaker on the ground as shown. Use safe operated from the driver's cab.
and correct lifting equipment to move the breaker.
Agree with the assistant on clear hand signals.The
2 Drive the Machine Squarely up to the Hammermaster assistant must be instructed by the excavator driver.
and stop.
!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2
13 333/A9900-3 13
Installation
3 Engage the Dipper 7 Remove the hydraulic pipe end caps
Carefully operate the controls to line up hole A in the 8 Make sure hammer hoses are clean.
dipper with holes B in the Hammermaster hanger
bracket. Insert pivot pin and secure it with clip. 9 Connect the hoses to hydraulic pipes, making sure
you install them the right way round, i.e. not crossed
The hanger pivot bush is drilled for a locking bolt to over.
retain the pivot pin, Make sure the pivot pin is inserted
the correct way for installation of the retention bolt 10 Always tighten hydraulic components with correct
tightening torque.
4 Engage the Tipping Link
11 Open the shut-off valves, as shown at P.
Operate the bucket ram lever to align tipping link E
with holes F in the Hammermaster hanger bracket. Most shut of valves can be locked in the open position
Insert pivot pin and secure with clip/bolt. to prevent them closing due to vibration during
operation.
Note: Wear clean oil proof gloves to prevent Oil contact
with skin when disconnecting or connecting 12 Remove the handles or position them close to the
dipper to reduce the chance of damage or accidental
!MWARNING movement
Hydraulic oil at pressure can injure you. Make the 13 Make sure the carrier machine is in hammer mode
machine safe as detailed below before removing the with the correct engine speed. Refer to the carrier
hose blanking plug. Follow the instructions below for machine manual for further details.
connecting the hoses.
8-4-1-3 Refer to the Changing Tools.
Note: It is recommended that carrier machine of JS 115 Note: For Hammermaster operating instructions, refer to
and above are installed with ball valves to reduce the carrier Operator Handbook.
amount of oil lost during connection, ball valve kits are
available from your JCB dealer.
Note: Do not use QRCS on JS excavators.
5 Stop the Engine and make the Carrier Safe
Refer to the Carrier Operator Handbook.
6 Valves
a If ball valves are installed make sure the Shut-off

Valves are fully closed (as shown at N) before
proceeding. Slowly undo the caps, beware of
trapped pressure.
b If the pipe work is simply capped off, undo the

caps slowly in case of trapped pressure, Be ready
to catch any oil draining out of the pipe work
c If QRCS are installed, make sure the mating faces

are clean, connect the correct QRC to the correct
mating QRC and proceed to 13
14 333/A9900-3 14
Installation
Installing to JCB Robot (Skid Steer

Loader)
For additional parts, refer to the 980/B0332 installation kit.
This frame is intended to be used with HM026T, HM033T,

or HM049T. It is suggested to use the universal version. if
a dipper mounted version is used, the hoses and hanger is
to be removed.
1 Assemble the rockbreaker. K Fig 3. ( T 15)
C D
E
G
A
P048180-01
Fig 3.
2 Tighten all the bolts to 250 N.m.
3 Connect the hoses. Make sure that the female QRC

connects to the "p" or "n" on the rockbreaker body.
Note: The hoses and adapters used are dependent on the

type of rockbreaker used.
4 Clamp the hoses in the hose clamp.
Note: Due to the variety of the hose terminations on JCB

machines, the QRC's may need changing. K Hose
Assesories ( T 74)
15 333/A9900-3 15
Removal
Removal
N P
A
B
F
P046730-43
Fig 4.
!MWARNING 3 Close the Shut-off Valves
If two people are doing this job make sure that the Make sure that the shut-off valves installed at the
person working the controls is a competent operator. dipper end are fully closed (as shown at N) before
If the wrong control lever is moved, or if the controls proceeding.
are moved violently, the other person could be killed
or injured. 4 Disconnect the Hydraulic Hoses
B-2-1-8
Disconnect the hoses and fit the end caps.
1 Position the Hammermaster
Rest the Hammermaster flat on hard level ground.

!MWARNING
Metal Splinters
!MWARNING You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
Hydraulic oil at pressure can injure you. Make the or copper pin to remove and fit metal pins. Always
machine safe as detailed below before disconnecting wear safety glasses.
the hoses. INT-3-1-3_2
8-4-1-4
5 Remove the Pivots Pins.
2 Stop the Engine and make the carrier safe.
K Installation and Removal ( T 11). a Unlock and remove clip from tipping link pivot.
Withdraw the pivot pin.
b Unlock and remove clip from dipper pivot pin.

Withdraw the pivot pin.
16 333/A9900-3 16
Removal
6 Withdraw the Dipper.
Start the carrier and using the controls, carefully lift

the dipper clear of the Hammermaster.
Non JCB Carriers

For Hammermaster on non-JCB Carriers you should refer
to the carrier manufacturer's instructions for removing or
installing attachments. However, the following general
points should always be observed:
1 Make sure that the Hammermaster is positioned on

firm, level ground before installing/removing it.
2 If the Hammermaster has to be in the vertical position

for installing/removing, ensure that the tool is
removed and that the Hammermaster is supported
safely.
3 Make the carrier safe, e.g. parking brake engaged,

engine stopped, hydraulic pressure released from
Hammermaster supply hoses.
17 333/A9900-3 17
Tools
Tools
HM012T - HM049T 6 Lift the tool retaining pin C out using the bolt.
1 Take the Load Off the Tool. 7 Remove the tool.
Use the machine or carrier controls to position the 8 Clean the tool shank and retaining pin B. Lubricate all
breaker horizontally. wearing and contact faces with JCB Extreme
Performance Hammer Grease.
2 Vent the Hydraulic Pressure.
a If you are proposing to install a used tool, first
a Stop the engine. check it for wear. K Lower Tool Bushing and
Tools ( T 15).
b Switch ON the starter switch.
b Check lower tool bushing for wear, replace if
c Operate the excavator and hammermaster necessary. K Lower Tool Bushing and
controls a few times to vent pressure in the Tools ( T 15)
system.
9 Install the tool, aligning the slots with the holes in the
d Remove the starter key. housing.
e Engage the parking brake, if applicable. 10 Install the retaining pin C.
3 Remove the upper rubber plug E. 11 Replace the rubber sealing plug E.
4 Install the bolt to the tool ratainer pin C.

E
F
C B
G
H
P046730-07
Fig 6.
P046730-58
Fig 5.
5 Push the spring loaded pin above the tool retaining

pin C sideways.
18 333/A9900-3 18
Tools
HM080T - HM380T
1 Take the Load Off the Tool.
Use the machine or carrier controls to position the

breaker horizontally.
2 Vent the Hydraulic Pressure.
a Stop the engine.
b Switch ON the starter switch.
c Operate the excavator and hammermaster

controls a few times to vent pressure in the
system.
d Remove the starter key.
e Engage the parking brake, if applicable.

P046730-58
Fig 7.
3 Remove the upper plugs covering the tool retainer pin
E. 8 Remove the tool.
4 Remove the upper side plugs H and F. 9 Clean the tool shank and the retaining pin B.
5 Use a hammer and punch to knock out the retainer 10 Re-install the tool.
pin B. The pins will only knock out one way this will be
from the other side of from the retainer plug G. a This is basically the opposite to removal, inspect
the pins and the tool retainers for wear and
6 Make sure that the retainer plug G is not lost. burring.
Note: The retainer plug will come out with sufficient b If you are proposing to install a used tool, first
velocity to travel some distance (drape a cloth over the check it for wear. K Lower Tool Bushing and
side of the breaker to capture the retainer plug G) Tools ( T 15).
7 Lift out the tool retainer pin C, using the bolt. If the tool c Check lower tool bushing for wear, replace if
retainer pins are seized in the hosing, remove the necessary. K Lower Tool Bushing and
lower plug E, the lower side plugs F and H and punch Tools ( T 15)
out the lower retaining pin B.
d Grease the lower bush and the contact faces of
Note: These plugs must always be replaced after the tool with JCB Extreme Hammer Grease.
installation of pins.
19 333/A9900-3 19
Tools
15 Replace the rubber sealing plugs E, F, and G.
E
F
C B
G
H
P046730-07
Fig 10.
P046730-60
Fig 8. Bushes Coated In Grease
P046730-59
Fig 9. Contact Faces Coated In Grease.
11 Install the tool, aligning the slots with the holes in the
housing.
12 Install the retainer pin C.
Note: The tool retainer pin can be reversed to extend the

life, coat all contacting surfaces with JCB Extreme
Hammer Grease.
13 Install the retainer pin B.
14 Replace the pin retainer plug G.
20 333/A9900-3 20
Storage
Storage
Note: Points to remember, when preparing the Hammer 9 Re-install the plug.
master for long term storage.
OR
1 Store the Hammermaster in a vertical position.

K Fig 12. ( T 21)
2 Make sure the Hammermaster is supported rigidly.
P046730-24
Fig 11.
1 Make sure that the storage area is dry.
2 Remove the tool.
3 Drain the gas from the low pressure accumulator P046730-25
using the gas charging kit, leave the charging valve Fig 12.
open.
4 Liberally cost the lower end of the piston, the tool(s)

and the bushings with grease.
5 Remove the caps from the capped hoses or connect

a mating QRC, if QRCs are installed. Be prepare to
collect any oil that is spilled.
6 Push the piston into the housing.
7 Put caps on the hoses to prevent ingress of dirt and

moisture, if QRCs are not installed.
8 Close the low pressure accumulator charging valve.
21 333/A9900-3 21
Storage
22 333/A9900-3 22
Operation
General Safety
Operation
General Safety
Safety First Principles of Breaking
!MWARNING The basic way of breaking with a hydraulic breaker is

penetrative (or cutting).
Read this book carefully before operating the
Hammermaster for the first time. Protect yourself and Penetrative Breaking
others against flying debris. Wear protective eye
glasses and ear plugs when operating the In this form of breaking a conical or chisel-type tool is
Hammermaster. Stop the carrier engine before forced inside the material. This method is most effective in
changing the tool or servicing the Hammermaster. soft, layered or plastic, low abrasive material.
B-2-1-4_1
!MDANGER
Danger Zone
Stop the hydraulic breaker immediately as soon as
persons are in the danger zone.
The danger zone during the breaker operation is

considerably greater than during the excavation
operation - on account of fractions of stones and
pieces of steel flying around - and for this reason, the
danger zone must, depending on the type of material
to be worked on, be enlarged correspondingly, or the
danger zone must be secured in a suitable manner P033480-07
through corresponding measures. Fig 1.
ATT021
Impact Breaking
Start and Stop the Hammermaster
Impact breaking transfers a very strong mechanical stress
Consult the Carrier's Operator Handbook for details of from a blunt ended steel into the material to be broken.
operating procedures and engine speed setting to achieve Impact breaking is most effective in hard, brittle and very
the required hydraulic oil flow. abrasive materials such as rocks. Impact breaking may not
be suitable for smaller breakers due to their relatively low
Note: Practice with the Hammermaster off the job before blow energy.
working with it for the first time.
P033480-09
Fig 2.
23 333/A9900-3 23
Operation
Tool
Tool
Selection of the Right Tool

The standard tools available for the hydraulic breaker are CHISEL MOIL
described below. The different tip geometries will influence
production performance depending on the type of job.
Please refer to the following table for application
recommendations.
Note: Only genuine tools may be used. If other makes of

tools are used, the warranty will cease to apply.
Sharp tips produce better results. Re-sharpening is

possible using a suitable coolant.
Sedimentary and
weak metamorphic
The tools must be adequately cooled during re-machining rock into which tool
using a suitable coolant. penetrates
Never weld or flame-cut the tools.

Concrete
The high temperatures involved will modify the
Trenching
microstructure of the tool.
Benching
Standard Tools
P033480-12
Fig 3.
Tool Name Illustration Application
Table 1.
Moil Universal use
MODEL TOOL PART NUMBER
HM080T Moil Tool 336/A6968
P029610-14
Flat chisel Mining, Chisel 336/A6971

cross-cut foundations, HM090T Moil Tool 336/A6977
trenching, Chisel 336/A6979
P029610-15
demolition
The illustration below shows basically the uses for some of Chisel 336/A6989
the tools. K Fig 3. ( T 24). HM160T Moil Tool 336/A6996
For advice on choosing the correct tool contact your JCB Chisel 336/A6997
Distributor. HM180T Moil Tool 331/67310
Chisel 331/67311
Chisel 336/A7133
Chisel 333/A3668
Chisel 336/A7146
24 333/A9900-3 24
Operation
Breaking - Do's and Don'ts
To ensure long life the hammermaster requires correct set Do

up and size the hammer matched for the job. "If a small
breaker is used on a job that requires a much larger
breaker, its life will be shortened. by forcing the breaker to Do position the tool against the work
do more than it was designed to do, "A large breaker can surface at an angle of 90o
do a smaller job or break smaller material however the
operator may not have the control."
The hydraulic systems must also be set to match the This is the most effective angle of attack and also reduces
particular hammer used. Hammers are designed to run wear in the chuck and the chances of tool breakage.
within a defined range of hydraulic pressures and flows.
Operating out side these limits will either shorten its life or
result in poor performance
Point to Remember
– On first installation - commision
90 o
– Lubricate tool and tool retainer pins before
installation.Use hammer grease not universal
greaseMonitor grease mark on tool.Monitor grease
usage.Manual greasing with tool fully pushed
in.When removing ensure ports are capped.Reset
relief valve if a higher pressure attachment is
installed.Change carrier machine oil twice as P033480-06
regular.Change hammer return filter regularyStand Fig 4.
clear of the tool when gas chargingEnsure the return
line is open when gas chargingAlways use a gas Do use the carrier boom to press the
charging kit with a regulator suitable for the job.On breaker firmly against the material.
double acting machines understand the action of both
ARV'sGet trained.
To stop excessive vibration.
Do reposition the tool often.
This prevents heat build up at the tool point and between

the piston and the tool.
Do use the benching method to break

hard or frozen ground.
Start at the middle and remove the material, then continue

outwards, breaking the material in towards the centre.
25 333/A9900-3 25
Operation
before the tool breaks through the material. Blank Firing
causes rapid wear to the tool retainer and shank of the tool.
Note: On first assembly of the tool into the hammermaster

Make sure the took bush, the tool retention pins and the
contact face of the tool with the bushes are coated in JCB
Extreme Performance Hammer Grease.
P033480-08
Fig 5.
Do stop if there is sudden resistance
under the ground.
There could be an underground utility, such as a pipe or an

armoured electrical cable. Indicated by a change in engine
or breaker noise.
Note: The illustrations on this and the following page are

typical only, it is not meant to represent any particular
breaker.
Do prevent `blank firing'.
P046730-27
Fig 6.
This occurs if the breaker is operated with the tool not

pressed against a solid material. The internal shock that
this produces can damage the breaker. Stop the breaker
just before the material breaks apart.Avoid blank firing
when the material breaks up. Shut off the hammer just
26 333/A9900-3 26
Operation
Don't
Don't strike one spot more than 15secs. at

a time. Unless there are signs of
penetration.
If the material hasn't yielded by this time it probably isn't

going to. All that will happen is that the tool will overheat,
shortening its life.
Don't strike and bend with the tool at the

P033480-11
same time. Fig 8.
Don't let the breaker run idle. Always
press the breaker against the material.
There are two reasons for this: you will be wasting blow
energy, because the tool is not at 90° to the material, and
you could damage the tool, its strength is along its length,
not across its width. Or you will get `blank firing'.
Don't use the breaker as a lever. Don't let the boom or dipper rams reach
the end of their travel when the breaker is
operated.
This could damage the machine's hydraulic rams.
Don't begin normal operation in low

temperatures until the breaker is warmed
up.
The tool could fail due to brittle fracture if it is operated at

low temperatures. The warm up process involves running
the engine for 5 - 10 minutes, followed by breaking
operations at 2/3 recommended engine speed for a further
5 - 10 minutes.
P033480-10
Fig 7. Don't immerse the breaker in mud or
water beyond the depth of the tool.
Don't use the tool as a lifting hook.
Ingress of mud or water above the top of the tool can cause
a pressure build-up between the piston and tool, resulting
in serious damage to the breaker. Special conversion kits
are available to allow underwater breaking.An air
compressor will also be required.
27 333/A9900-3 27
Operation
!MCAUTION 2 Replace or fix all parts that are worn out, damaged or
loosened. this not only saves your breaker but it
The breaker as a standard assembly, must not be used decreases the noise level.
under water. If water fills the space where the piston
strikes the tool, a strong pressure wave is generated 3 To break effectively, a proper thrust force has to be
and the breaker may be damaged. applied to the breaker.
B-2-1-16
If a thrust is insufficient, impact energy of the piston is
Do not use the hammer master as a sledge hammer not efficient enough for breaking rocks. Then, the
breaking force is transferred to the breaker body, arm
and boom of the carrier etc. to result in damage of
those parts.
P046730-29
Fig 9.
When the dig end is used, always keep the drive sprockets
at the rear. The stability of the machine is improved and
wear to the drive is decreased.
P046730-34
Fig 11.
4 Excessive contact force will cause the carrier to be

raised, the machine may suddenly tilt forward as the
rocks are broken damaging the carrier machine
undercarriage or breaker body.
P046730-30
Fig 10.
Noise Dampening
Operating the breaker near residential areas or other noise
exposure areas can cause noise pollution.
In order to avoid unnecessary noise, please follow these

basic rules:
1 When operating with the breaker, keep the tool at 90°

to the material. Working at other angles increases the
noise level by 5 - 8 dB. P046730-35
Fig 12.
28 333/A9900-3 28
Operation
5 Do not burry the breaker body, this will damage the
housing and force debris into the tool bush.
P046730-39
Fig 16.
8 Do not operate with the cylinders at the end of their

stroke.
P046730-36
Fig 13.
6 Never use the breaker to move rocks, this puts stress

on the hanger bolts.
P046730-37
Fig 14.
P046730-40
Fig 17.
P046730-38
Fig 15.
7 Never sweep with the breaker.
29 333/A9900-3 29
Operation
Preparation
Preparation
Protective measures should be taken to rule out the risk of

accidents and injuries:
– Operator to be trained and competent.

– Operator should wear ear protection to prevent
hearing impairment. Anyone in the immediate vicinity
of breaker operations should also wear ear
protection.
– Operator should wear suitable breathing mask when
working in highly dusted environment.
– Make sure the hydraulic attachment is prepared to
work in surrounding weather conditions and ambient
temperature. P046730-28
– Close the front screen / splinter guard on the driver's Fig 18.
cab to avoid injury from flying rock splinters.
– Carry out a couple of test impacts on the material to
be broken.
– Check the hydraulic lines and make sure that the
hydraulic attachment works correctly.
Note: Immediately switch off the hydraulic attachment if oil

escapes from the hydraulic system or if any other defects
in functioning occur.
Seat Position
Set up seat correctly to reduce fatigue to the operator.
During operation monitor the hoses of the breaker for

vibration. Excessive vibration can indicate low charge
pressure in the high pressure accumulator, contact your
JCB dealer.
Note: Check for oil leaks.
Note: Inspect the tool is free when the breaker is lifted, If

not, the tool could be seized in the bush.
30 333/A9900-3 30
Operation
Preparation
Adjuster valve to control impact blows

The blow energy of breaker is adjusted by the stroke
adjuster valve, this gives a long or short piston stroke
Job condition for stroke adjustment
– At secondary job of lime stone and soft rock, high

speed is more productivity.
– At primary and hard rock breaking job, power (low
speed) outputs more.
Blows of breaker
The blows of breaker can be adjusted with following

procedure.
1 Release the nut of adjuster.
2 High speed (Low power) : turn adjuster to counter-

clockwise. (turn 2 cycle).
3 Low speed (High power) : turn adjuster to clockwise.

(fully tighten)
P046730-41
Fig 19.
4 Tighten the nut of adjuster after setting.
31 333/A9900-3 31
Operation
The Effects of Blank Firing
The Effects of Blank Firing
If the breaker is operated without the tool being pressed

against a solid material (known as `blank firing') both the
breaker and the tool can be damaged. Damage can be
caused to the breaker by the internal shocks which
develop in the hydraulic components. Blank firing also
causes rapid wear to the tool retainer pin and the tool itself.
Typically, damage is in the form of heavily burred edges on
the tool and retainer pin as shown. Such damage is usually
not repairable and therefore adds extra (and unnecessary)
costs and delays to the job.
To prevent blank firing:

1 Never operate the breaker without a tool.
2 Never operate a breaker unless the tool is pressed

against a solid surface.
3 Stop the breaker just before the tool breaks through

the material.
P033480-13
Fig 20. Do Not Blank Fire
P033480-14
Fig 21. The effects of blank firing on tool and retaining
pin.
32 333/A9900-3 32
Operation
Travelling with the Hammermaster
Travelling with the Hammermaster
On Site On a Truck
Position the Hammermaster as shown when travelling.For Position the Hammermaster as shown. Ensure that the
further information refer the carrier machine manual. attachment cannot be operated while being transported.
Note: When driving the machine up and down the loading

ramps, keep the Hammermaster at the end furthest from
the truck cab and as near the ground as possible.
Note: The Hammermaster shown is typical and does not

refer to a particular Hammermaster.
!MWARNING
The safe transit of the load is the responsibility of the
P046730-04
Fig 22. transport contractor and driver. Any machine,
attachments or parts that may move during transit
must be adequately secured.
5-2-5-9
Note: Before transporting the machine make sure you will

be obeying the rules and laws of all the areas that the
machine will be carried through.
Use straps or chains or chains over the body or through the

pivot bores, no not place the chains or straps over the tool,
automatic greaser or the hoses.
P046730-45
Fig 23.
33 333/A9900-3 33
Operation
Hydraulic Oils, Filtering and Cooling
Introduction Special Oils

Generally speaking the hydraulic oil specified for the In some cases special oils (e.g. biological oils and non
carrier can be used in the Hammermaster. However, since inflammable oils) can be used with the Hammermasters.
working with the Hammermaster will heat the oil much observe the following aspects when considering the use of
more than excavation work, the viscosity of the oil must be special oils.
checked periodically when working in hot climates.
– The viscosity range in the special oil must be in the
When the Hammermaster is used continuously, the given range (15 - 1000 cSt).
temperature of the hydraulic oil normalises at a certain – The lubrication properties must be good enough.
level depending on conditions and the carrier. At this
– The corrosion resistance properties must be good
temperature, the viscosity of the hydraulic oil should be 20
enough.
- 40 cSt (2.90 - 5.35 oE).
Note: Although a special oil could be suitable for the
The Hammermaster must not be started if the viscosity of
carrier, it may not be suitable for the Hammermaster, due
the hydraulic oil is above 1000 cSt (131oE) or operated
to the high piston speed. Please check with your JCB
when the viscosity of the hydraulic oil is below 15 cSt (2.35
Distributor.
o
E).
JCB owners should always consult their JCB distributor
Possible Result of using incorrect Oil before changing the machine hydraulic oil.
Oil too thick: Hydraulic Oil Purity

– Difficult start up.
No additional filter is required for the Hammermaster. The
– Stiff operation. carrier's oil filter will clean the oil flowing through the
– Hammermaster strikes irregularly and slowly. Hammermaster. The purpose of the oil filter is to remove
– Danger of cavitation in the pumps and impurities from the hydraulic oil since they cause
Hammermaster. accelerated component wear, blockages and even
seizure. Impurities also cause the oil to heat and
– Sticky valves. deteriorate. Air and water are also impurities in oil. Not all
– Filter bypass, impurities in oil not removed. impurities can be seen with the naked eye.
Oil to thin: Impurities enter the hydraulic system:
– Efficiency losses (internal leaks). – During operation.

– Damage to gaskets and seals, leaks. – During hydraulic oil changes and refilling.
– Accelerated wearing of parts, because of decreased – When components are repaired or serviced.
lubrication efficiency. – When the Hammermaster is being installed on the
carrier.
Note: We recommend different hydraulic oils for use in
summer and winter if there is an average temperature – Because of component wear.
difference of more than 35 oC (95 oF).
34 333/A9900-3 34
Operation
Oil Filter
In hydraulic hammer work, the carrier oil filter must fulfil the
following specifications:
– The oil filter must allow maximum particle size of 25

microns (0.025 mm).
– The oil filter material must be man-made fibre cloth or
very fine gauge metallic mesh to withstand pressure
fluctuations.
– The oil filter must have a volume flow capacity of at
least twice the Hammermaster's maximum flow.
In general, oil companies guarantee new oils to have a

particle count of 40 microns maximum. When adding oil to
the system the oil must be filtered.
35 333/A9900-3 35
Operation
36 333/A9900-3 36
Maintenance
Health and Safety
Safety First Lubricants
!MWARNING In the EEC all JCB lubricants are covered by individual

COSHH (Control of Substances Hazardous to Health)
Maintenance work must only be done by competent leaflets which are available on request from your JCB
personnel. Distributor.
A-3-1-1
It is most important that all personnel concerned with
!MWARNING lubricants read and understand the information contained
in the relevant leaflets.
Equipment Condition
Defective equipment can injure you or others. Do not Some general guidance is given in the JCB Carrier
operate equipment which is defective or has missing Machine Handbook.
parts.
Make sure the maintenance procedures in this manual

are completed before using the equipment.
A-1-4-1
!MWARNING
Before doing any routine maintenance work on the
attachment while it is installed on a carrier, make the
carrier safe. Stop the engine and, if appropriate,
ensure that the park brake is engaged and the drive is
in neutral. Remove the starter key to prevent the
engine being started.
B-3-1-2_3
37 333/A9900-3 37
Maintenance
Service Requirements
Service Requirements
Main Inspection Obtaining Replacement Parts

We recommend that the following inspection is done We recommend that you fit only genuine JCB replacement
during the first 50 - 100 hours of operation of a new parts. Your distributor will need to know the equipment's
Hammermaster installation. It is advisable to have this serial number, which is stamped on the Hammermaster
work done by your JCB Distributor. data plate.
Check Washing
1 Torque tightness of the housing/hanger bracket Periodically, and before doing any maintenance work, we
securing bolts/nuts. recommend that the outside of the Hammermaster is
steam-washed. Ensure that the pressure and return lines
2 All hydraulic connections. are plugged before washing, to prevent ingress of
moisture.
3 For hoses rubbing against carrier (throughout range
of rotation of the Hammermaster).
4 Hammermaster operating pressure.
5 Hydraulic oil temperature during continuous

operation.
6 Hammermaster efficiency, impact rate and evenness

of operation.
7 Lower tool bushing for wear. K Lower Tool Bushing

and Tools ( T 50).
8 Tool and retaining pins.
(Check for cracks on the tool retaining pins due to

blank firing. Check retaining pins for large burrs. Do
not re-use if excessively burred.)
9 Change the hydraulic filter(s).
10 Check the low pressure accumulator - pressure must

only be checked with no load on the tool.
Note: Head Hydraulic pressure must only be checked with

no load on the tool.
38 333/A9900-3 38
Maintenance
Service Schedules
Service Schedules
!MWARNING
Maintenance work must only be done by competent
personnel.
A-3-1-1
To make sure your Hammermaster keeps working to

maximum efficiency, it is essential that it is properly and
regularly maintained in accordance with the service
schedules included in this handbook.
Badly maintained equipment can be a danger to the

operator and the people working around him. Make sure
that the regular maintenance and lubrication jobs listed in
the service schedules are done to keep the equipment in a
safe and efficient working condition.
Do not use equipment which is due for a service. Make

sure that any defects found during the regular
maintenance checks are rectified before you use the
equipment.
Grease
Breakers up to and including HM054T can use JCB
Hammer grease or JCB Extreme Hammer grease,
breakers over HM054T must use JCB extreme Hammer
grease.
Table 1.
Item Part no.
JCB Hammer Grease 400 gm 4003/1119
cartridge
JCB Extreme Hammer Grease 12.5 4003/2106
kg barrel
JCB Extreme Hammer Grease 400 4003/2107
gm cartridge
Manual Grease Gun for JCB Extreme 992/11300
Hammer Grease
39 333/A9900-3 39
Maintenance
Service Schedules
Every 2 - 4 Hours (Depending on Typically the grease should coat the length of the tool
exposed from the breaker body equal to the diameter of
operating conditions)
the tool.
Grease The level of grease in the auto greaser should slowly be
gradually used up.
Make sure that the tool is greased and the autogrease is
working properly.
P029691
Fig 1.
Manual Lubrication
Manual lubrication is necessary if the automatic lubrication

fails. For manual lubrication, stand the hydraulic breaker
upright on the working tool and apply contact pressure.
Lubricating intervals: Approximately every 2 hours.

Apply 15 - 25 shots of Extreme Performance Hammer
Grease from a grease gun.
Note: Grease performs two jobs: lubricates and clears the

tool bushing area of abrasive debris. Excess of grease can
cause a build up between the strike piston and the tool
absorbing energy. Too little grease creates a lapping
compound increasing wear on the tool and lower bush.
40 333/A9900-3 40
Maintenance
Service Schedules
Daily Observe (Hammermaster Operation)
Do the 2-4 hour jobs plus: 13 Operating pressure, hydraulic oil temperature, blow
efficiency and evenness of operation.
1 Clean the Hammermaster, its tools, its hoses and
quick release couplings. If the impact energy weakens check the low pressure
accumulator.
2 Grease the Hammermaster pivots (see the carrier
handbook for actual frequency and method). 14 Check the hoses for excess vibration - if the hoses
pulsate stop and check the high pressure
3 For damage to the Hammermaster, its tools and its accumulator pressure.
hoses. Tighten loose fasteners and connections.
15 Visually check for any excess oil staining.
4 Visually check the tightness of the hanger bracket
securing bolts. 16 Check carrier machine instrumentation for high
temperature or blocked filters.
5 All hydraulic connections.
Note: Piston accumulator gas pressure must only be
6 Damage to hoses rubbing - replace if necessary checked with no load on the tool.
7 Lower tool bushing for wear. Visual inspection Weekly

8 Tool and retaining pins. The torque tightness of the hanger bracket securing bolts.
9 Tool tip Do the 2-4 hour and daily jobs plus:
10 Grease around the lower bush area. Check (engine stopped)
11 Quantity of grease in the auto lube system. 1 Remove the retaining pins B and the tool retention
pins C.
12 Ball valves are open.
P046730-07
Fig 2.
41 333/A9900-3 41
Maintenance
Service Schedules
2 Remove the tool. 1 Overhaul the Hammermaster.
Inspect for adequate lubrication. 2 With the Hammermaster installed on the carrier,
measure the circuit oil flows and back pressure.
3 Measure the shank for excessive wear, replace the
tool if necessary. 3 Renew hydraulic filters of carrier.
4 Check hoses do not foul the boom/dipper throughout

D their ranges of movement.
5 Check operating pressure, hydraulic oil temperature,

blow efficiency and evenness of operation.
6 Renew Hammermaster warning decals.
7 Check accumulator and recharge if necessary.

D
!MWARNING
Modifications and Welding
The accumulator(s) in the Hammermaster are
pressurised even when there is no hydraulic pressure
to the breaker. Never tamper with an accumulator.
P046730-05 Attempting to dismantle an accumulator without first
Fig 3. releasing the pressure can cause injury or death. Such
work should only be carried out by qualified servicing
4 Inspect the tool for burrs. personnel who have studied the relevant Service
Manual.
5 Inspect the tool retaining pins for burrs and signs of B-1-3-7
blank firing.
Note: Service intervals should be reduced in certain
6 Remove burrs if necessary. applications, such as hammer tunnelling, scaling, smelter
cleaning and underwater use. If in doubt, consult your JCB
7 Measure the lower tool bushing for excessive wear - Distributor.
replace if necessary
8 Lubricate the lower bush and tool before re- !MDANGER

installation the tool Use only nitrogen gas to charge accumulators. The
use of any other gas can cause the accumulators to
9 Replace the tool retention pin indexed round 180 explode. Remember that although nitrogen is not
degrees to spread the wear poisonous you can be killed by suffocation if it
displaces the air in your workplace. Do not allow
10 Replace the retaining pin and caps. excessive quantities of nitrogen to be discharged into
the atmosphere.
Note: Operation of the breaker with excessive tool to lower
B-3-1-6_2
bush wear will severly shorten the breakers life Check the
low pressure accumulator pressure Important: If you do not understand any part of this
document seek advice from your employer or JCB
Every 500 Hours or Yearly (whichever Distributor
occurs first)
This annual service is best carried out by the JCB
Distributor.
42 333/A9900-3 42
Maintenance
Service Schedules
Checking the low pressure accumulator
!MDANGER
Use only nitrogen gas to charge accumulators. The
explode. Remember that although nitrogen is not
poisonous you can be killed by suffocation if it
excessive quantities of nitrogen to be discharged into
the atmosphere.
B-3-1-6_2
Important: If you do not understand any part of this

Distributor
P046730-08
Check the low pressure accumulator shown is a boxed Fig 4.
breaker version for side plate versions there is no access
cover.
Note: Checking should be done with no load on the tool

and the ports open, if mounted on a machine the hoses
can remain connected if the return line is open to tank so
not to trap pressure.
Keep clear of the tool at all times
Note: To avoid errors checking of accumlator pressure

should be done after its allowed to cool, ensure the
nitrogen cylinder is not exposed to extremes of
temperature.
Note: Wear gloves an safety glasses.
1 Remove the acees cover.

P046730-12
Fig 5.
2 Remove the charging plug.
43 333/A9900-3 43
Maintenance
Service Schedules
P046730-11
Fig 6. P046730-13
Fig 8.
3 Unscrew the pin in charging adaptor if screwed
in.K Fig 7. ( T 44). 5 Connect the nitrogen gas cylinder to the nitrogen
regulator
Note: For some countries nitrogen cylinder adaptors will

be required - see table
6 Connect the link hose to the nitrogen regulator.
7 Connect the other end of the link hose to the charging

adaptor.
Note: Make sure the bleed valve on the regulator

assembly is closed.
8 Turn the hand wheel on the charging adaptor

clockwise to open the charging port connection.
9 Read the pressure on the regulator gauge.
10 Check gas pressure to the chart K Conversion table

for charging N2-gas pressure to back
head ( T 49).
If the pressure is correct close the charging valve by

turning the hand wheel anti-clock wise.
if the pressure is low.
11 Slowly Open the valve on the nitrogen bottle
12 Slowly increase the pressure on the nitrogen cylinder

regulator until it reaches the upper limit of the correct
P046730-10 pressure
Fig 7.
13 Close the nitrogen gas bottle valve.
4 Screw the charging adaptor into the charging port on
the power cell head. 14 Turn the hand wheel anti clockwise on the charging
adaptor to close the charging port.
15 Recheck pressure in 5 to 15 minutes time.
16 Remove the charging adaptor.
44 333/A9900-3 44
Maintenance
Service Schedules
17 Place a few drops of oil into the charging port, check Checking the high pressure accumulator
for nitrogen leakage.
Note: This should be only done on commissioning the
18 Replace the charging port cap and tighten to 1 - 3 Nm. breaker or if loss of charge is suspected.
Note: The charging port of the larger breakers differ from

the smaller breaker. Below is detailed the method of
checking and charging the larger breaker. The smaller
breaker have a charging port similar as the low pressure
accumulator.
!MDANGER
Use only nitrogen gas to charge accumulators. The
explode. Remember that although nitrogen is not
poisonous you can be killed by suffocation if it
excessive quantities of nitrogen to be discharged into
the atmosphere.
B-3-1-6_2
Important: If you do not understand any part of this

Distributor
Check the low pressure accumulator shown is a boxed

breaker version for side plate versions there is no access
cover.
Note: Checking should be done with no load on the tool

and the ports open, if mounted on a machine the hoses
can remain connected if the return line is open to tank so
not to trap pressure.
Keep clear of the tool at all times
Note: To avoid errors checking of accumlator pressure

should be done after its allowed to cool, ensure the
nitrogen cylinder is not exposed to extremes of
temperature.
Note: Wear gloves an safety glasses.
1 Remove the access cover.
45 333/A9900-3 45
Maintenance
Service Schedules
P046730-14
P046730-08 Fig 11.
Fig 9.
3 Remove the cap over the filling valve.
P046730-12
Fig 10. P046730-15
Fig 12.
2 Remove the charging plug.
4 Make sure the pin of the adaptor is screwed into the
body of the charging adaptor.
46 333/A9900-3 46
Maintenance
Service Schedules
6 Connect the nitrogen gas cylinder to the nitrogen
regulator, for some countries an adaptor may be
required - see nitrogen cylinder adaptor chart.
7 Connect the link hose to the nitrogen regulator.
8 Connect the other end of the link hose to the charging

adaptor.
P046730-21
Fig 15.
9 Open the filling valve 1 - 1.5 turns with an allen key -

note there is no need to turn the hand wheel on the
P046730-10
Fig 13. accumulator charging adaptor.
5 Screw the charging adaptor into the charging port on

the high pressure accumulator top.
Make sure the area is clean.
P046730-20
Fig 14.
47 333/A9900-3 47
Maintenance
Service Schedules
P046730-23
Fig 17.
20 Replace the charging port plug and tighten to 1 - 3

Nm.
P046730-22
Fig 16. 21 Replace the charging valve cap - tighten to 1 - 3 Nm.
10 Read the pressure on the regulator gauge.
11 Check gas pressure to the specification section the

JCB model numbers will have to be used.
If the pressure is low.
12 Slowly open the valve on the nitrogen bottle.
13 Slowly increase the pressure on the nitrogen cylinder

regulator until it reaches 2-3 bar above the correct
pressure.
14 Close the nitrogen gas bottle valve.
15 Close the charge port valve to close the charging port.
16 Recheck pressure in 5 to 15 minutes time.
17 Close the valve on the nitrogen cylinder.
18 Remove the charging adaptor.
19 Place a few drops of oil into the charging port, check

for nitrogen leakage.
48 333/A9900-3 48
Maintenance
Service Schedules
Conversion table for charging N2-gas

pressure to back head 22
21
For Model Number: e
20 sur
pres
– HM012T 19 rge
cha

Gas pressure kg/cm
– HM026T 18 as
dg
mde
– HM049T 17 me
– HM054T recom
16 of
ge
– HM080T 15 e ran
– HM090T Th
14
13
18 12
11
17
10
16 -20 0 20 40 60 80
Ambient temperature C ( F)
P P

Gas pressure kg/cm
15
re
ssu
P046730-32
14 pre Fig 19.
rge
13 cha
gas
ed For Model Number:
12 md
mme
o
11 of rec
ge – HM018T
e ran
10 Th – HM120T
9 – HM160T
8 – HM180T
7 – HM200T
6 – HM270T
-20 0 20 40 60 80
– HM380T
P P
P046730-31
Fig 18.
22
For Model Number: 21
– HM033T 20
19

Gas pressure kg/cm
18 re
ssu
e pre
17 rg
cha
16 gas
mded
e
15 mm
f reco
14 o
ge
e ran
13 Th
12
11
10
-20 0 20 40 60 80
P P
P046730-33
Fig 20.
49 333/A9900-3 49
Maintenance
Lower Tool Bushing and Tools
Lower Tool Bushing and Tools
Checking For Excessive Wear Check for and Removal of Burrs

1 Remove the tool as described in Tools - Installing and 1 Remove the tool as described in Tools - Installation
Removing. and Removal
2 Check Bush and Tool wear limits. 2 Check for burrs on the tool shank and the retaining
pin.
3 Replace the lower tool bushing as described in Lower
Tool Bushing. 3 Carefully remove all burrs. Do not overheat the tool.
!MCAUTION
Protect yourself when removing burrs. Wear safety
glasses and industrial gloves.
B-3-1-4_1
4 Smear the tool shank and the bushing with JCB

Extreme Hammer Grease before installing the tool.
50 333/A9900-3 50
Maintenance
Wear Limits and Tool for Lower Tool Bushing
Note: It is assumed that the tool has been removed. This Tool Wear Limits
inspection can be carried out with the bushing still in
position.
Tool Retention Pin Wear Limits
P046730-48
Fig 22.
P046730-47 NEW WEAR LIMIT WEAR LIMIT

Fig 21. (X) (Y)
NEW WEAR LIMIT mm Inch mm Inch mm Inch
mm Inch mm Inch HM012T 45 1.77 43 1.69 41 1.61
HM012T 25 0.98 23 0.91 HM018T 57 2.24 55 2.17 53 2.09
HM018T 30 1.18 28 1.1 HM026T 70 2.76 68 2.68 66 2.6
HM026T 36 1.42 34 1.34 HM033T 75 2.95 73 2.87 71 2.8
HM033T 42 1.65 40 1.57 HM049T 90 3.46 88 3.46 86 3.39
HM049T 37.5 1.48 35.5 1.4 HM054T 90 3.46 88 3.46 86 3.39
HM054T 37.5 1.48 35.5 1.4 HM080T 95 3.74 93 3.66 91 3.58
HM080T 36 1.42 34 1.34 HM090T 105 4.13 103 4.06 101 3.98
HM090T 50 1.97 47 1.85 HM120T 115 4.53 113 4.45 111 4.37
HM120T 70 2.76 67 2.64 HM160T 135 5.31 133 5.24 131 5.16
HM160T 70 2.76 67 2.64 HM180T 135 5.31 133 5.24 131 5.16
HM180T 80 3.15 77 3.03 HM200T 145 5.71 143 5.63 141 5.55
HM200T 95 3.74 92 3.62 HM270T 155 6.1 153 6.02 151 5.94
HM270T 97 3.82 94 3.7 HM380T 175 6.89 172 6.77 170 6.69
HM380T 100 3.94 96 3.78
51 333/A9900-3 51
Maintenance
Upper Dampener Wear Limits Lower Dampener Wear Limits
P046730-50
Fig 24.
NEW WEAR LIMIT (C)
mm Inch mm Inch
P046730-49
Fig 23. HM012T NA NA NA NA
NEW WEAR LIMIT (B) HM018T 20 0.79 18 0.71
mm Inch mm Inch HM026T 20 0.79 18 0.71
HM012T NA NA NA NA HM033T 20 0.79 18 0.71
HM018T 54 2.13 52 2.05 HM049T 20 0.79 18 0.71
HM026T 78 3.07 75 2.95 HM054T 20 0.79 18 0.71
HM033T 78 3.07 75 2.95 HM080T 20 0.79 18 0.71
HM049T 78 3.07 75 2.95 HM090T 20 0.79 18 0.71
HM054T 78 3.07 75 2.95 HM120T 20 0.79 18 0.71
HM080T 100 3.94 96 3.78 HM160T 20 0.79 18 0.71
HM090T 100 3.94 96 3.78 HM180T 25 0.98 22 0.87
HM120T 110 4.33 106 4.17 HM200T 25 0.98 22 0.87
HM160T 110 4.33 106 4.17 HM270T 25 0.98 22 0.87
HM180T 125 4.92 121 4.76 HM380T 25 0.98 22 0.87
HM200T 125 4.92 121 4.76
HM270T 125 4.92 121 4.76
HM380T 125 4.92 121 4.76
52 333/A9900-3 52
Maintenance
Upper Bush Wear Limits Bottom Bush Wear Limits
P046730-52
Fig 26.
WEAR LIMIT (F)
P046730-51 mm Inch
Fig 25.
HM012T 3 0.12
WEAR LIMIT (D) WEAR LIMIT (E)
HM018T 3 0.12
mm Inch mm Inch
HM026T 3 0.12
HM012T 5 0.2 NA NA
HM033T 3 0.12
HM018T 5 0.2 NA NA
HM049T 4 0.16
HM026T 5 0.2 NA NA
HM054T 4 0.16
HM033T 5 0.2 13 0.51
HM080T 4 0.16
HM049T 6 0.24 15 0.51
HM090T 4 0.16
HM054T 6 0.24 15 0.51
HM120T 4 0.16
HM080T 6 0.24 9 0.35
HM160T 5 0.2
HM090T 6 0.24 14 0.55
HM180T 5 0.2
HM120T 6 0.24 9 0.35
HM200T 6 0.24
HM160T 7 0.28 15 0.59
HM270T 7 0.28
HM180T 7 0.28 8 0.31
HM380T 7 0.28
HM200T 8 0.31 8 0.31
HM270T 9 0.35 13 0.51
HM380T 9 0.35 22 0.87
53 333/A9900-3 53
Maintenance
Retainer Pin Wear Limits
P046730-53
Fig 27.
NEW WEAR LIMIT (H)
mm Inch mm Inch
HM012T 10 0.39 8 0.31
HM018T 10 0.39 8 0.31
HM026T 10 0.39 8 0.31
HM033T 15 0.59 13 0.51
HM049T 10 0.39 8 0.31
HM054T 10 0.39 8 0.31
HM080T 17.5 0.69 15.5 0.61
HM090T 17.5 0.69 15.5 0.61
HM120T 17.5 0.69 15.5 0.61
HM160T 17.5 0.69 15.5 0.61
HM180T 17.5 0.69 15.5 0.61
HM200T 17.5 0.69 15.5 0.61
HM270T 21.5 0.85 19.5 0.77
HM380T 27.5 1.08 25.5 1
54 333/A9900-3 54
Maintenance
Housing Pad Wear Limits
P046730-54
Fig 28.
STANDARD VALUE WEAR LIMIT STANDARD VALUE WEAR LIMIT
J K
mm inch mm inch mm inch mm inch
HM012T 106 4.17 109 4.29 106 4.17 109 4.29
HM018T 114 4.49 117 4.61 135 5.31 138 5.43
HM026T 132 5.2 135 5.31 142 5.59 145 5.71
HM033T 152 5.98 155 6.1 162 6.38 165 6.5
HM049T 177 6.97 180 7.09 177 6.97 180 7.09
HM054T 177 6.97 180 7.09 177 6.97 180 7.09
HM080T 202 7.95 205 8.07 202 7.95 205 8.07
HM090T 222 8.74 225 8.86 222 8.74 225 8.86
HM120T 232 9.13 235 9.25 232 9.13 235 9.25
HM160T 252 9.92 255 10.04 252 9.92 255 10.04
HM180T 272 10.71 275 10.83 272 10.71 275 10.83
HM200T 282 11.1 285 11.22 282 11.1 285 11.22
HM270T 322 12.68 325 12.8 322 12.68 325 12.8
HM380T 342 13.46 345 13.58 342 13.46 345 13.58
55 333/A9900-3 55
Maintenance
Automatic Greasing System
Automatic Greasing System
P046730-46
Fig 29.
Grease Nipple for

manual greasing of the
Breaker
Lock Nut
Adjuster
Fully Closed (Min. Output)

Direction of
Fully Open (Max. Output)
rotation of
the Adjuster
Grease Nipple for grease

refilling of the cartridge
P033480-30
Fig 30.
56 333/A9900-3 56
Maintenance
Disposal of Consumable
End of Life Disposal

Dispose of the hydraulic breaker and the hydraulic oil in
accordance with the applicable statutory provisions on
environmental protection in your local area.
Important: The hydraulic breaker is pressurised with

nitrogen gas. While disposing the breaker, the high and
low pressure Accumulators must be first depressurised by
qualified personnel.
Hydraulic oil has to be drained from the hydraulic lines and

disposed in accordance with the applicable environmental
regulations.
57 333/A9900-3 57
Maintenance
58 333/A9900-3 58
59
Specification
Machine Specification
JCB HM012T HM018T HM026T HM033T HM049T HM054T HM080T HM090T HM120T HM160T HM180T HM200T HM270T HM380T
MODEL
Operating kg 120 187 260 330 495 545 800 900 1,150 1,580 1,800 2,000 2,700 3,800
Weight lb 265 412 573 728 1091 1202 1,764 1,984 2,535 3,483 3,968 4,409 5,952 8,378
Overall mm 1,135 1,450 1,513 1,639 1,894 2,062 2,125 2,234 2,442 2,589 2,775 2,906 3,085 3,580
Length inch 44.69 57.09 59.57 64.53 74.6 81.18 83.66 87.95 96.14 101.93 109.25 114.41 121.46 140.94
Tool mm 45 57 70 75 80 90 95 105 115 135 135 145 155 175
Diameter inch 1.77 2.24 2.76 2.95 3.15 3.54 3.74 4.13 4.53 5.31 5.31 5.71 6.1 6.89
Carrier - - - - - - - 210 210 210 210 210 230 210
Relief - - - - - - - 3,000 3,000 3,000 3,000 3,000 3,300 3,000
Valve
Setting
Operating bar 90~120 90~120 110~165 120~165 140~170 140~170 140~180 140~190 140~190 160~190 160~190 160~190 160~190 150~190
Pressure psi 1280~ 1280~ 1565~ 1700~ 1990~ 1990~ 1990~ 1,990~ 1,990~ 2,275~ 2,275~ 2,275~ 2,275~ 2,130~
333/A9900-3
1700 1700 2350 2350 2420 2420 2560 2700 2700 2700 2700 1700 2700 2700
JCB 90~120 90~120 110~165 120~165 140~170 140~170 160~170 160~170 160~170 160~170 160~170 160~170 160~170 150~170
Recomme
nded
Data Plate
Pressure
Oil Flow l/m 12~25 23~70 29~65 34~76 38~85 42~94 63~102 68~119 85~127 115~155 119~161 127~178 170~238 204~272
gal/ 3.2~6.6 6.1~18.5 7.7~17.2 9~20.1 10.0~ 11.1~ 16.4~27 18~31.5 22.5~ 30.5~41 31.5~ 33.5~47 45~63 54~72
min 22.5 24.8 33.5 42.5
Blow Rate bp 550~ 600~ 380~ 380~900 400~800 350~700 350~600 350~550 320~550 320~480 340~450 270~400 230~400 230~330
Low m 1000 1500 1000
Blow Rate - - - - 600~ 490~ 600~900 600~900 400~700 400~600 420~550 400~700 270~470 270~500
High 1100 1000
Low bar 10~14 14~16 10~14 16~18 10~14 10~14 10~14 10~14 14~16 14~16 14~16 14~16 14~16 14~16
Pressure psi 142-199 199-228 142-199 228~256 142~199 142~199 142~199 142~199 199~228 199~228 199~228 199~228 199~228 199~228
Accumulat
or
59
Specification
JCB HM012T HM018T HM026T HM033T HM049T HM054T HM080T HM090T HM120T HM160T HM180T HM200T HM270T HM380T
60
MODEL
High bar - - - 40~50 40~50 40~50 55~60 55~60 55~60 55~60 55~60 55~60 55~60 55~60
Pressure psi - - - 569~711 569~711 569~711 782~853 782~853 782~853 782~853 782~853 782~853 782~853 782~853
Accumulat
or
Carrier ton 0.8~2.5 1.5~4.0 3~6.5 4.5~8 4.5~8 6~10 10~15 10~15 12~18 18~24 20~26 24~30 28~42 40~60
Weight lbs 1760~ 3300~ 6600~ 9900~ 9900~ 13200~ 17600~ 22,000~ 26,500~ 39,700~ 44,100~ 52,900~ 61,700~ 88,200~
5500 8800 14300 17600 17600 22000 27500 33,000 40,000 53,000 57,500 66,000 92,500 132,500
333/A9900-3
60
Specification
Specification
Torque Settings
Torque Settings
BSP Hose Connection
Breaker BSP Thread size Dash size Recommended Max. Remedial

torque (Nm) Torque (Nm)
HM012T 1/2 -8 50-55 72
HM018T 1/2 -8 50-55 72
HM026T 1/2 -8 50-55 72
HM033T 3/4 -12 85-94 126
HM049T 3/4 -12 85-94 126
HM054T 3/4 -12 85-94 126
HM080T 3/4 -12 85-94 126
HM090T 3/4 -12 85-94 126
HM120T 1 -16 115-127 153
HM160T 1 -16 115-127 153
HM180T 1 -16 115-127 153
HM200T 1 1/4 -20 190-209 234
Code 62 SAE Flange Coupling
Breaker Nominal SAE flange SAE dash size Metric coarse Recommended
size (inch) fastener torque (Nm)
HM270T 1 1/4 -20 M12 56-68
HM380T 1 1/4 -20 M12 56-68
61 333/A9900-3 61
Specification
Torque Settings
62 333/A9900-3 62
Service
Fault Finding
Problem Cause Solution Remarks

The Breaker does not Connected back wards Check connections: P =
start or Run pump/pressure line T = tank/
return line
Auxilliary ball valve closed Check connections Use retainer to open
lock
Switch spool siezed Contact your JCB dealer Inspect
No load on tool Blank fire protection needs
load on tool
Non genuine tool
Too low pressure setting on carrier Contact your JCB dealer Inspect
machine
Too much pressure in low Piston can not lift
pressure accumulator
High Back pressure Piston can not lift Check return line and
renew filter
Oil leaked into low pressure Piston can not lift
accumulator
Piston failure Contact your JCB dealer
The Breaker runs slow Too much pressure in low Forcing oil over relief valve Combined with
pressure accumulator overheating
Low relef valve setting Low flow
High pressure accumulator high Forcing oil over relief valve
on gas pressure
Incorrect restrictor Too small Forcing oil over relief
valve
Insufficient oil flow Correct pump mode
Pilot pressure valve pressure
setting
Ball valve partially closed Check Use retainer to lock
open
Oil leaked into low pressure Check
accumulator
Correct setting of adjuster valve Check
Check stroke valve Adjust
63 333/A9900-3 63
Service
Fault Finding

Loss of breaking power Loss of precharge in HP Check pressure If problem persists
accumulator inspect accumualtor -
also hose vibration
Check for debris Strip breaker and
clean
Loss of precharge in LP Check pressure If problem persists
accumulator inspect piston and
seal
Low flow Carry out flow and pressure Worn machine or
check on machine faulty ARV/MRV
Machine in wrong setting See opertaor manual
Ball valve partially closed Check Use retainer to lock
open
May lead to over
heating
Over heating Check cooling capacity Drop in oil viscosity
Check oil grade Incorrect oil viscosity
Worn piston and bore High internal leakage
Ball valve partially closed Check and lock open
if necessary
Oil degraded Loss of viscosity / increased Take oil sample for
leakage analysis
Over greasing allowing
grease past piston seal
Loss of precharge in low pressure Check and adjust if Always check at the
accumulator neccesary correct temperature
and recheck 5
minutes later
Hose vibration Loss of precharge in HP Check / Adjust and re-check If problem persists
accumulator 5 minutes later inspect HP
accumualtor
64 333/A9900-3 64
Service
Fault Finding

Lack of lubrication Increase lubrication Adjust CONTI LUBE Grease mark should
equal diameter of tool
Cartridge empty Replace / Refill
Cartridge damaged Inspect Lubrication system
Seal missing sucking in air
Cartrigde not screwed IN

Cartrigde end not open Inspect Check
Over Heated Check machine set up and Grease melts and
cooling runs out
Check operator technique Observe 15s rule
Worn tool or bush Lubricant escapes Wear accelerated
Debris enteres at a greater Wear accelerated
rate
Oil leaking from tool Piston seal leaking Inspect piston and seal Damaged piston seal
bush due to debris
Check tool and bush Damaged piston due
clearance to tool being struck at
an angle
Run in hammer mode Lack of lubrication -
bush wear causing
piston failure leading
to seal failure
Trapped pressure
Over Heated Seals worn / brittle Check condition of
carrier machine and
set up
Check operator technique Observe 15s rule
Lack of lubrication Debris in chamber Accelerated wear of
piston seal
Face operation Debris in chamber Accelerated wear of
piston seal
Low temperature operation Seal stiff Pre warm up
Accelerated wear due to Oil by passing filter
contamination
Seal installed incorrectly Most possible cause after a
service
Leaking from housing Hose connections Check hose connections Life shortened by in
correct setup
General seal failure Check Re commission /
check carrier machine
65 333/A9900-3 65
Service
Fault Finding

Tool wear Lack of lubrication Renew bush and tool Check lubrication rate
after commissioning
No initial lubrication of tool on
assembly
Incorrect operator technique Observe 15 second rule
None perpendicular tool to Ensure tool is square to face Tool bush oval
material
Worn tool bush Replace Check lubrication rate
after commissioning
Worn retainer pins slots Use of moil instead of chisel Twisting of tool,
replace retainer pins if
necessary
Tip break up / mushroomed Over heated Observe 15s Rule /
Operator technique
Retention pin wear Use of chisel in rebar Torsion loading on
reinforced concrete tool
Bush wear Lack of lubrication Renew bush and tool Check lubrication rate
after commissioning
No initial lubrication of tool on
assembly
Incorrect operator technique Observe 15 second rule
None perpendicular tool to Make sure tool is square to Tool bush oval
material face
Worn tool Replace Check lubrication rate
after commissioning
Tool retention pin wear Use of chisel in rebar reinforced Torsion loading on tool Use a moil
concrete
Lack of lubrication Check for visible grease
mark on tool
Pins not rotated to extend life Rotate pins
Incorrect commissioning Grease pins on initial
assembly
Piston / Tool break up Angular piston contact with tool Renew piston, tool and tool Full strip down and
bush inspection of piston
and barrel
Severe wear due to lack of See all faults
lubrication associated with lack
of lubrication
Over speeding To high oil flow
Operation under water Pressure shocks
66 333/A9900-3 66
Service
Fault Finding

Errosion of internal Wear due to contamination Wear leading to change of Renew filter, check oil
parts operation or overheating
Pitting due to air in hydraulics Wear leading to change of Renew filter, check
operation or overheating oil, oil may smell burnt
Snapped tool Levering rock Break smaller pieces and Do not lever with tool
observe 15s rule
Low temperature operation Store in doors Warm up slowly
Over heating Carrier machine has insufficient Seek advice
cooling
Oil viscosity / condition out of Excessive internal leakage
specification
Worn breaker Excessive internal leakage
Machines ARV/ MRV incorrect Oil passing over relief valve Carry out loop test
creating heat
Operating at too high flow rate Re-commission installation
Machine in wrong setting See opertaor manual
High pressure accumulator high Forcing oil over releif valve
on gas pressure
Too much pressure in low Forcing oil over releif valve Combined with runs
pressure accumulator slow
67 333/A9900-3 67
Service
Fault Finding
68 333/A9900-3 68
Part Numbers
Breaker Models
MODEL MACHINE FITMENT PICKUP PART COMPRISES OF

NUMBER Breaker Installation
Kit
HM012T Micro 25mm x 90mm CRS 980/A6283
Universal Flange 242 x 242mm 980/A6282
1-2T Compact Excavator Range 30mm x 120mm CRS 980/B4944
HM018T 802 , 8025, 8030, 8035, 804 (130crs only) 35mm x 130mm CRS 980/B0260
8020 25mm x 90mm CRS 980/B0261
1CX 35mm x 130mm CRS 980/B0263
Universal Flange 300 x 260mm 980/B0262
HM026T 803, 8035 804 35mm x 130mm CRS 980/B0254
47Z,51C,55Z&56C 45mm x 245mm 980/B0259
2CX 3CX Compact 1 1/4" x 231mm CRS 980/B0256
HM033T 8052 - 8086 65R, 67C, 85Z 86C 85Z 86C 1 3/4" x 343mm CRS 980/B0251
90Z 100C
48/55ZTS/51RTS/57CTS 45mm x 245mm 980/B0258
3CX, 4CX, 5CX 1 3/4" x 343mm CRS 980/B0250
HM049T 8080 - 8086 85Z 86C 85Z 86C 90Z 100C 1 3/4" x 343mm CRS 980/B0264
4CX 1 3/4" x 343mm CRS 980/B0265
HM054T 8080 - 8086 85Z 86C 85Z 86C 90Z 100C 1 3/4" x 343mm CRS 980/B0264
4CX, 5CX 1 3/4" x 343mm CRS 980/B0265
HM080T JS130 - 145 Including JZ Varients 65mm x 385mm CRS 980/B0200 980/B0222 980/B0235
HM090T JS130 - 145 Including JZ Varients 65mm x 385mm CRS 980/B0201 980/B0223 980/B0235
JS160 - 190 80mm x 435mm CRS 980/B0202 980/B0223 980/B0236
JS 200W 80mm x 450mm CRS 980/B0203 980/B0223 980/B0237
HM120T JS 160 - 190 80mm x 435mm CRS 980/B0204 980/B0206 980/B0238
JS200W 80mm x 450mm CRS 980/B0205 980/B0206 980/B0239
69 333/A9900-3 69
Part Numbers
Breaker Models
MODEL MACHINE FITMENT PICKUP PART COMPRISES OF

NUMBER Breaker Installation
Kit
HM160T JS 200 - 220 Including JZ Varients 80mm x 450mm CRS 980/B0207 980/B0209 980/B0239
JS 240/260 90mm x 490mm CRS 980/B0208 980/B0209 980/B0240
HM180T JS200 - 220 80mm x 450mm CRS 980/B0210 980/B0212 980/B0241
JS240 - 260 90mm x 490mm CRS 980/B0211 980/B0212 980/B0242
HM200T JS240 -240 90mm x 490mm CRS 980/B0213 980/B0215 980/B0243
JS290 90mm x 565mm CRS 980/B0214 980/B0215 980/B0244
HM270T JS290 - 370 90mm x 565mm CRS 980/B0216 980/B0218 980/B0245
JS450 - 500 100mm x 570mm CRS 980/B0217 980/B0218 980/B0246
HM380T JS 460 100mm x 570mm CRS 980/B0221 980/B0224 980/B0247
70 333/A9900-3 70
Part Numbers
Nitrogen Adaptor Reference Chart
Table 1. Country Adaptor Part No

Country Adaptor Part No
Germany Direct ***

Algeria 40h 892/01202
Ghana 40b 892/01196
Argentina 40b 892/01196
Greece 40h 892/01202
Armenia 40n 892/01207
Guatemala 40g 892/01201
Australia 40b 892/01196
Guinea 40h 892/01202
Austria Direct ***
Guyana 40g 892/01201
Azerbaijan 40n 892/01207
Honduras 40g 892/01201
Bahamas 40b 892/01196
Hongkong 40b 892/01196
Bahrain 40h 892/01202
Hungary 40h 892/01202
Bangladesh 40b 892/01196
India 40b 892/01196
Barbados 40b 892/01196
Indonesia 40b 892/01196
Belgium Direct ***
Iran 40h 892/01202
Bolivia 40g 892/01201
Iraq 40h 892/01202
Botswana 40b 892/01196
Ireland 40b 892/01196
Brazill 40g 892/01201
Israel 40h 892/01202
Bulgaria 40n 892/01207
Italy 40d 892/01198
Burma 40b 892/01196
Ivory Coast 40h 892/01202
Canada 40c 892/01197
Jamaica 40b 892/01196
Chile 40g 892/01201
Japan 40e 892/01199
China 40k 892/01204
Jordan 40h 892/01202
Colombia 40g 892/01201
Jugoslavia 40h 892/01202
Costa Rica 40b 892/01196
Kazakhstan 40n 892/01207
Czech Republic Direct ***
Kenya 40b 892/01196
Denmark Direct ***
Korea 40f 892/01200
Djibouti 40h 892/01202
Kuwait 40h 892/01202
Dom. Republic 40g 892/01201
Kyrgyzstan 40n 892/01207
Ecuador 40g 892/01201
Lebanon 40h 892/01202
Egypt 40b 892/01196
Libya 40h 892/01202
Ethiopia 40b 892/01196
Lichtenstien Direct ***
Fiji 40b 892/01196
Luxembourg Direct ***
Finland Direct ***
Malawi 40b 892/01196
France 40h 892/01202
Malaysia 40l 892/01205
Gabon 40h 892/01202
Malta 40b 892/01196
Gambia 40b 892/01196
Mauritius 40h 892/01202
Georgia 40n 892/01207
71 333/A9900-3 71
Part Numbers
Country Adaptor Part No Country Adaptor Part No
Mexico 40h 892/01202 Turkey 40b 892/01196

Moldova 40n 892/01207 Turkmenistan 40n 892/01207
Morocco 40h 892/01202 Ukraine Direct ***
Mozambique 40h 892/01202 United Arab 40h 892/01202
Netherlands Direct *** Emirates
New Zealand 40b 892/01196 Great Britain 40b 892/01196
Nigeria 40h 892/01202 Uruguay 40g 892/01201
Norway Direct *** USA 40c 892/01197
Oman 40h 892/01202 Uzbekistan 40n 892/01207
Pakistan 40b 892/01196 Venezuela 40n 892/01207
Paraguay 40g 892/01201 Vietnam 40b 892/01196
Peru 40g 892/01201 Zambia 40b 892/01196
Philippines 40b 892/01196

Poland Direct ***
Portugal 40b 892/01196
Puerto Rico 40c 892/01197
Qatar 40k 892/01204
Romania 40h 892/01202
Russ.Feder 40n 892/01207
Saudi-Arabia 40h 892/01202
Singapore 40b 892/01196
Slovakia Direct ***
Slovenia Direct ***
South Africa 40b 892/01196
Spain 40h 892/01202
Sri Lanka 40b 892/01196
Sudan 40b 892/01196
Surinam 40b 892/01196
Swaziland 40b 892/01196
Sweden Direct ***
Switzerland Direct ***
Syria 40h 892/01202
Taiwan 40b 892/01196
Tanzania 40b 892/01196
Thailand 40b 892/01196
Trinidad or Tobago 40m 892/01206
Tunisia 40h 892/01202
72 333/A9900-3 72
Part Numbers
P046730-26
Fig 1.
73 333/A9900-3 73
Part Numbers
Hose Assesories
Hose Assesories
Due to variety of hose terminations on JCB machines, the

QRC's may need changing. These part number apply to
models HM018T, HM026T, HM033T, and HM049T.
Description Part Number

1/2" QRC Male 45/910500
1/2" QRC Female 45/910400
1/2" Dowty Seal 1406/0018
1/2" - 1/2" Adaptor 1604/0004
3/4" QRC Male 45/910300
3/4" QRC Female 45/908400
3/4" - 1/2" Adaptor 1606/0009
3/4" - 3/4" Adaptor 1604/0006
3/4" Dowty Seal 1406/0021
1"QRC Male 45/910100
1" QRC Female 45/910200
1" - 3/4" Adaptor 1606/0012
1" - 1/2" Adaptor 1606/0010
1" Dowty Seal 1406/0026
Hose - 1/2" x 2155 mm 613/01600
Hose - 1/2" x 2250 mm 613/31300
Hose - 1/2" x 2370 mm 613/02200
Hose - 3/4" x 2150 mm 615/80103
Hose - 3/4" x 2400 mm 615/05100
Male Fitting
P048180-02
Fig 2.
Dimension (X mm) Size (inch)
20 1/2
25 3/4
30 1
74 333/A9900-3 74

JCB HM012T, HM018T, HM026T, HM033T, HM049T, HM054T, HM080T, HM090T, HM120T, HM160T, HM180T, HM200T, HM270T, HM380T Large Hydraulic Breakers O1 PDF

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JCB HM012T, HM018T, HM026T, HM033T, HM049T, HM054T, HM080T, HM090T, HM120T, HM160T, HM180T, HM200T, HM270T, HM380T Large Hydraulic Breakers O1 PDF

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JCB LARGE HYDRAULIC BREAKERS

HYDRAULIC BREAKERS (HM SERIES)

Contents Page No.

Installation and Removal

Contents Page No.

Contents Page No.

In case of use in special conditions, contact your JCB

Check List - Equipment

1 Breaker - assembled with mounting side plates.

5 JCB Extreme Hammer Grease Cartridge. HM 012T - HM 018T

6 Noise Warning Decal (self adhesive). A

Place chains or slings to lift the breaker. K Fig 3. ( T 3).

To stabilise the lift additional straps can be used with

Note: Do not lift using tool.

Safety - Yours and Others Safety Warnings

All machinery can be hazardous. When a machine is

But safety is not just a matter of responding to the !MDANGER

Safety Label Identification

Note: The annotation on each label refer to the machine

2. ISO-06A 6. Label-Sound Power

3. Label-N2 7. Label-Grease Point

Page left intentionally blank

Installation and Removal

1 Tool might move unexpected inside the breaker.

2 Tool and breaker may have sharp edges. Wear safety

3 Working tool is heavy and might be hot. Wait until tool

Always follow the working tool installation and

Note: The illustration shows a typical Hammermaster and

!MWARNING Breaker models including and over HM080T use Allen

Lay the hydraulic breaker on squared beams or a pallet

Insert the elastic pad in the breaker box, ensuring it is the

Hangers are attached to the boxed versions with bolts

For boxed versions of breaker models HM012T to

Note: Do not use QRCS on JS excavators.

5 Stop the Engine and make the Carrier Safe

Refer to the Carrier Operator Handbook.

a If ball valves are installed make sure the Shut-off

b If the pipe work is simply capped off, undo the

c If QRCS are installed, make sure the mating faces

Installing to JCB Robot (Skid Steer

This frame is intended to be used with HM026T, HM033T,

1 Assemble the rockbreaker. K Fig 3. ( T 15)

2 Tighten all the bolts to 250 N.m.

3 Connect the hoses. Make sure that the female QRC

Note: The hoses and adapters used are dependent on the

4 Clamp the hoses in the hose clamp.

Note: Due to the variety of the hose terminations on JCB

!MWARNING 3 Close the Shut-off Valves

Rest the Hammermaster flat on hard level ground.

b Unlock and remove clip from dipper pivot pin.

Start the carrier and using the controls, carefully lift

Non JCB Carriers

1 Make sure that the Hammermaster is positioned on

2 If the Hammermaster has to be in the vertical position

3 Make the carrier safe, e.g. parking brake engaged,

1 Take the Load Off the Tool. 7 Remove the tool.

e Engage the parking brake, if applicable. 10 Install the retaining pin C.

4 Install the bolt to the tool ratainer pin C.