SERVICE MANUAL : HM 2180, HM 1180, HM 480 and HM 380

Service Manual

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.

Hammermaster HM 2180,
JCB Attachments, Riverside, Rugeley, Staffordshire WS15 2WA, England
Tel: 01889 572700

HM 1180, HM 480 and

332/A3098

332/A3098
??????????? ISSUE 1
HM 380
ISSUE 1

DEC 07
ENGLISH PAGES 1- 56
PAGES FRANÇAISES 1- 56F
DEUTSCHE SEITEN 1- 56G
PAGINAS EN ESPAÑOL 1- 56S
TESTO IN ITALIANO 1- 56L
PAGINA’S IN NEDERLANDS 1- 56Du
 CONTENTS

SAFETY NOTICES i
Workshop Standards i PARTS LIST
HM 2180/1180 - Power cell -Wear Parts 40
INTRODUCTION Power cell 2180/1180 - Illustration 41
About this Manual 1 Power Cell 2180/1180 - Parts List 42
Units of Measurement 1 HM 2180/1180 - Housing Illustration 45
Carrier Machine - Suitability 1 HM 2180/1180 - Parts List 46
Warranty 1 HM380 - Sideplates 47
Basic Description 1 HM 480 - Sideplates 48
Page Numbering 1 HM 380 - Power Cell - Illustration 49
HM 380 - Power Cell - Parts List 50
GENERAL DESCRIPTION HM 480 - Power Cell - Illustration 52
HM 480 - Power Cell - Parts List 53
Check List - Equipment HM 2180/1180 2
HM 380/480- Power Cell - Wear Parts 55
Attachment Identification 2
Component Identification 2
Lifting 2 WARRANTY(To be advised) At the rear of this
Check List - Equipment HM 380/480 3 book.
Attachment Identification 3
Component Identification 3
Lifting 3
NOTE
IF THE BREAKER HAS BEEN DISPATCHED FROM JCB
SAFETY
ATTACHMENTS BY AIR FREIGHT THE
Safety First 4
ACCUMULATOR NITROGEN GAS WILL HAVE BEEN
Safety Check List 4
DISCHARGED. THIS WILL REQUIRE RECHARGING
BEFORE THE BREAKER ENTERS SERVICE.
TECHNICAL SPECIFICATION
HM 380 6
HM 480 7
HM 1180 8
HM 2180 9
Power Cell Illustration 10

SERVICE
Dismantling 11
Inspection of Parts 13
Tool Retaining Pins 13
Wear Limits - Tool and front Bush 13
Wearing Parts 13
Removal of Parts & Deburring 14
Deburring 14
- Cylinder Bush 14
- Cylinder 15
- Use of the Buffer Cylinder 15
- Piston 16
- Damage on the Piston Contact Surface 17
Assembling 18
- Fitting a New Bush 18

CHARGING THE ACCUMULATORS 21

TORQUE TABLES 26

AUTOMATIC GREASING SYSTEM 27

Self Contained Recharging Greasing System 28
Parts List 30

SPECIFICATION
Requirements - HM 380 & HM 480 31
Requirements - HM 1180 & HM 2180 32

332/A3098-1
i SAFETY NOTICES
In this manual there are safety notices. Each notice
starts with a signal word. The signal word meanings
are given below.
? DANGER
Denotes an extreme hazard exists. If proper
precautions are not taken it is highly likely that you (or
others) could be killed or permanently injured.
INT-1-2-1
? WARNING
Denotes a hazard exists. If proper precautions are not
taken you (or others) could be killed or injured.
INT-1-2-2
? CAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
equipment.
INT-1-2-3
Workshop Standards
JCB HM Breakers have hydraulically powered percussion
mechanisms. Since all hydraulically powered equipment is
sensitive to dirt, the breakers must always be
disassembled in a place that is:
. Isolated from all dust and particle-generating
activities such as grinding and welding.
. Very clean,ie. free of dust and dirt.
. Equipped with washing facilities and compressed air
for the blow drying of components after washing.
. Equipped with all necessary standard and special tools.
332/A3098-1
i
? WARNING
The tool must not be modified without the
manufacturer’s permission. Use only original parts and
accessories approved by JCB Service. If modifications
are made that are not approved by JCB Service
serious harm to yourselves or others may result.
All users of this instruction manual are asked to inform
JCB Attachments if they find any errors or discrepancies,
especially any affecting product safety.
Use only authorized parts. Any damage or malfunction
caused by the use of unauthorized parts will not be
covered by any Warranty or Product Liability.
Any unauthorized use or copying of the contents of
this manual or any part hereof is prohibited. This
applies in particular to trademarks, model
denominations, part numbers and drawings.
Service Personnel
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by the JCB Training Centre or by JCB
Service Personnel. These personnel should have a sound
knowledge of workshop practice, safety procedures and
general techniques associated with the maintenance and
repair of hydraulic equipment.
Renewal of seals, gaskets etc. and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of
dirt. Finally, please remember above all else - SAFETY
MUST COME FIRST!
1 INTRODUCTION
About this Manual
This document details the relevant service and
maintenance procedures for the JCB Hammermaster HM
2180, HM 1180, HM480 and HM 380. The safety
information included is directly relevant to the service and
maintenance of the Hammermaster HM 2180, HM
1180,HM 480 and HM 380. General safety information,
and that relevant to the carrier machine is not included.
For details about safe operation of the carrier machine,
see the relevant documents.
DO NOT ATTEMPT TO INSTALL, OPERATE OR
MAINTAIN ANY ATTACHMENT UNTIL YOU HAVE
READ AND UNDERSTOOD ALL RELEVANT OPERATOR
DOCUMENTATION FOR BOTH THE ATTACHMENT
AND THE CARRIER MACHINE. PAY PARTICULAR
ATTENTION TO SAFETY INFORMATION. YOU MUST
OBSERVE ALL RELEVANT LAWS AND REGULATIONS.
The manufacturer’s policy is one of continuous
improvement. The right to change the specification of the
equipment without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
Units of Measurement
In this manual, the S.I. system of units is used. For
example, liquid capacities are given in litres. The Imperial
units follow in parenthesis ( ), for example 28 litres
(6 UK gal).
Carrier Machine Suitability
These Hammermasters are suitable for use with the
following JCB machines when fitted with a high flow
auxiliary/breaker hydraulic circuit. An installation kit,
suitable hanger bracket and a hose kit are available from
your JCB Distributor.
Hammermaster JCB Machine
HM 2180 JCB JS Excavators ‘carrier weight’-
21 to 32 tonnes.
HM 1180 JCB JS Excavators ‘carrier weight’-
12 to 20 tonnes.
HM 480 JCB JS Excavators ‘carrier weight’-
6 to 12tonnes.
HM 380 JCB JS Excavators ‘carrier weight’-
6 to 12 tonnes.
332/A3098-1
1
These Hammermasters are suitable for use with some non
JCB carrier machines. See the Specification section (See
Owner’s Manual ) for details of typical carrier
requirements. Contact your JCB Distibutor for advice.
Warranty
A copy of the manufacturer's warranty is provided at the
rear of the Owner’s manual. We advise you to read and
understand the warranty before using the machine.
FAILURE TO COMPLY WITH THESE
REQUIREMENTS MAY RESULT IN DELAYS IF A
WARRANTY CLAIM IS MADE. IF YOU HAVE ANY
DIFFICULTY UNDERSTANDING THESE
DOCUMENTS CONTACT YOUR JCB
DISTRIBUTOR.
Hammermaster Basic Descriptions
JCB Hammermasters are hydraulically operated breakers.
They can be used on any carrier which meets the
necessary hydraulic and mechanical installation
requirements. (See Carrier Requirements _ Owner’s
Manual).
Basically the breaker operates by repeatedly raising a
piston and driving it down onto the head of a removable
breaking or cutting tool. The breaker’s blow energy is
always consistent, provided that the supply pressure is
kept within the required limits (see SPECIFICATIONS).
Hydraulic pressure peaks are absorbed by the internal
pressure accumulator.
Page Numbering
The page numbering system in this manual is not
continuous. There is a gap of a few pages between some
sections. This allows for the insertion of new pages in later
issues.
2 GENERAL DESCRIPTION 2

Check List - Equipment Attachment Identification

The Hammermasters HM 2180 & HM 1180 are supplied as Serial Number - Always quote the serial number given on
follows: the breaker’s rating plate X when obtaining replacement
parts.
1 Breaker

2 Tail Hoses ?
3 Moil Tool/ Chisel

4 Grease

5 JCB Extreme Hammer Grease

6 Operator Handbook.

Component Identification
Key

A Housing
B Hanger Bracket Lifting
C Hydraulic Connections
D Tool Lifting devices must safely carry the working weight of
E Control Valve (behind plate) the product (see Specification). Place chains or slings
F Accumulator(behind plate) as shown in the illustration to lift the breaker.
G Lifting Point
The illustration shows the HM 2180, however the
HM 1180 is similar.

? ?
? ?
?

?
?
?

332/A3098-1
3 GENERAL DESCRIPTION 3

Check List - Equipment Attachment Identification

The Hammermaster HM 380 & HM 480 are supplied as Serial Number - Always quote the serial number given on
follows: the breaker’s rating plate B when obtaining replacement
parts.
1 Breaker
Lifting
2 Tail Hoses
Lifting devices must safely carry the working weight of the
3 Moil Tool/ Chisel product (see Specification). Place chains or slings as
shown in the illustration to lift the breaker.
4 Grease

5 JCB Extreme Hammer Grease

6 Operator Handbook.

Component Identification
Key

A Side Plates
B Data Plate
C Hydraulic Connections(behind plate)
D Tool
E Control Valve (behind plate)
F Accumulators (behind plate)

Note; There are two accumulators on these breakers,

for a full component breakdown see Power Cell parts
list at the rear of this manual.

? ?

? ?

The illustration shows the

HM 380, however the HM
480 is similar.

332/3098-1
4 SAFETY
Safety First
All mechanical equipment can be hazardous if operated
without care or correct maintenance.
In this manual you will find warning messages. Read them.
Understand them. They tell you of hazards and how to
avoid them. If you do not understand the messages, ask
your employer or local JCB Distributor.
But safety is not just a matter of responding to the
warnings. All the time you are working with the attachment
you must be thinking what hazards there might be and
how to avoid them.
Do not work with the attachment until you are sure that
you can control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the
job, ask someone who knows. Don’t assume anything -
check it out.
Remember
BE CAREFUL
BE ALERT
BE SAFE
Now read the rest of this section before moving on to the
rest of the manual.
B-1-1-2/1
Each safety notice starts with a signal word. The
meanings of the signal words are given below.
? ? DANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable
that the operator (or others) could be killed or
seriously injured.
INT-1-2-1
? ? WARNING
Denotes a hazard exists. If proper precautions are
not taken, the operator (or others) could be killed
or seriously injured.
INT-1-2-2
? CAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury
to the operator (or others) and possible damage to
the machine.
INT-1-2-3
332/A3098-1
4
Safety Check List
? ? DANGER
Lightning
Lightning can kill you. Do not use the equipment if there is
lightning in your area.
A-1-3-5
? ? WARNING
Decals
You can be injured if you do not obey the decal safety
instructions. Keep decals clean. Replace unreadable or
missing decals with new ones before operating the
machine. Make sure replacement parts include warning
decals where necessary.
INT-1-3-4
? ? WARNING
Equipment Condition
Defective equipment can injure you or others. Do not
operate equipment which is defective or has missing
parts.
Make sure the maintenance procedures in this manual are
completed before using the equipment.
A-1-4-1
? ? WARNING
The accumulator(s) in the hammermaster are pressurised
even when there is no hydraulic pressure to the breaker.
Never tamper with an accumulator. Attempting to
dismantle an accumulator without first releasing the
pressure can cause injury or death. Such work should only
be carried out by qualified servicing personnel who have
studied the relevant Service Manual.
B-1-3-7
? ? WARNING
Modifications and Welding
Non-approved modifications can cause injury and damage
Contact your JCB Distributor for advice before modifying
the equipment. Before welding on the Hammermaster
while it is installed on the carrier, disconnect the carrier
alternator and battery. Note that electric welding of the
Hammermaster tools will render them useless and make
the warranty void.
B-1-3-2/1
? ? WARNING
Protect your ears. Working with the Hammermaster
without wearing earmuffs can damage your hearing. Wear
earmuffs when working with the hammer.
B-2-1-11
5 SAFETY 5

Safety Check List (cont’d)

? CAUTION
Every breaker has its own flow requirement. If the machine
is not preset to deliver the correct flow for the breaker
fitted, either the breaker will not function correctly or the
machine may be damaged.

Whenever a breaker or hammer is fitted, it is ESSENTIAL

that the engine speed is correctly preset to suit the
breaker.

Have your JCB dealer reset the engine speed before using
the machine with a new breaker fitted. This is a specialist
job and the machine can be seriously damaged if it is not
done correctly.
8-2-8-12

? ? CAUTION
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in and out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3

? ? CAUTION
Take care when lifting/handling. Refer to SPECIFICATION
for the attachment weight.
B-2-1-2/2

? ? CAUTION
Equipment Limits
Operating the equipment beyond its design limits can
cause damage. It can also be dangerous.

Do not operate the equipment outside its limits.

Do not try to upgrade the equipment’s performance by

unapproved modifications.
A-1-4-2

332/A3098-1
6 TECHNICAL SPECIFICATIONS 6

Hammermaster HM 380

Working weight (including tool) 330 kg (728 lb)

Overall Length (including tool) 1398 mm (55in)

Impact rate (frequency) 380 - 900 blows/min

Operating pressure 120 - 165 bar (1740- 2393 lbf/in2 )

Carrier Pressure relief - minimum Measured operating pressure plus 60 bar

Carrier Pressure relief - maximum 175 bar (2500 lbf/in2 )

Oil supply 40 - 80 l/min (10.2 - 20.3 gal/min)

Maximum return line back pressure 10 bar (145 lbf/in 2)

Impact energy 981 Joules

Port adaptors - Hammermaster/connecting hoses

Pressure line 3/4 in BSP (male)
Return line 3/4 in BSP (male)

Oil
Temperature range - 20 °C + 80 °C (- 4 °F + 176 °F)
Viscosity 1000 - 15 cSt.

Carrier weight 6 - 12 tonne (13228 -26455 lb)

Tools
Shank diameter (new) 75 mm (2.95 in)
Shank diameter (minimum allowable) 69 mm (2.72 in)

Bushings
Diameter (new) 75 mm (2.95 in)
Diameter (maximum allowable) 81 mm (3.2 in)

HP Accumulator charging pressure 40-50 bar (570-710 lbf/in 2)

Piston Accumulator Pressure 16-18 bar (230-260 lbf/in2) Check with no load on tool.

Noise 116 db (A)

JCB Nitrogen Kit part number 998/11323

332/A3098-1
7
TECHNICAL SPECIFICATIONS 7

Hammermaster HM 480

Working weight (including tool) 495kg (1089 lbs)

Overall Length 1640mm(64.5in)

Impact rate (frequency) 400 - 1100 blows/min

Operating pressure 140 - 170 bar (2030- 2465 lbf/in2)

Carrier Pressure relief - minimum measured operating pressure plus 60 bar

Carrier Pressure relief - maximum 175 bar (2500lbf/in2 )

Oil supply 45 - 90 l/min (11.8 - 23.7 gal/min)

Maximum return line back pressure 10 bar (145 lbf/in2 )

Impact energy 1187 Joules

Port adaptors - Hammermaster/connecting hoses

Pressure line 3/4 in BSP (male)
Return line 3/4 in BSP (male)

Oil
Temperature range - 20 °C + 80 °C (- 4 °F + 176 °F)
Viscosity 1000 - 15 cSt.

Carrier weight 12 - 18 tonne (26455 - 39683 lb)

Tools
Shank diameter (new) 80mm (3.14in)
Shank diameter (minimum allowable) 72 mm (2.84 in)

Bushings
Diameter (new) 80 mm (3.14 in)
Diameter (maximum allowable) 88mm (3.46 in)

HP Accumulator charging pressure 40-50 bar (570-725 lbf/in2 )

Piston Accumulator Pressure 10-14 bar (145-200 lbf/in 2) Check with no load on tool

Noise 116 db (A)

JCB Nitrogen Kit part number 998/11323

332/A3098-1
8 TECHNICAL SPECIFICATIONS 8

Hammermaster HM 1180

Working weight (including tool) 1150 kg (2535 lb)

Overall Length 2441mm (96.1in)

Impact rate (frequency) 350 - 900 blows/min

Operating pressure 160 - 190 bar (2320- 2756 lbf/in2)

Carrier Pressure relief - minimum Measured operating pressure plus 60 bar

Carrier Pressure relief - maximum 210 bar (3046 lbf/in2)

Oil supply 100 - 150 l/min (26.4 - 39.6 gal/min)

Maximum return line back pressure 10 bar (145 lbf/in2 )

Input power (max) 48 kW

Port adaptors - Hammermaster/connecting hoses

Pressure line 1 in BSP (male)
Return line 1 in BSP (male)

Oil
Temperature range - 20 °C + 80 °C (- 4 °F + 176 °F)
Viscosity 1000 - 15 cSt.

Carrier weight 12 - 20 tonne (26455 - 44092 lb)

Tools
Shank diameter (new) 115 mm (4.53 in)
Shank diameter (minimum allowable) 111 mm (4.37 in)

Bushings
Diameter (new) 115 mm (4.53 in)
Diameter (maximum allowable) 119 mm (5.69 in)

HP Accumulator charging pressure 55-60 bar (780-850 lbf/in2 )

Piston Accumulator Pressure 10-16 bar (145-230 lbf/in 2) Check with no load on tool.

Noise 90 db (A)

JCB Nitrogen Kit part number 998/11323

332/A3098-1
9 TECHNICAL SPECIFICATIONS 9

Hammermaster HM 2180

Working weight (including tool) 1800 kg (3969 lb)

Overall Length 2775 mm (109.3in)

Impact rate (frequency) 340 - 800 blows/min

Operating pressure 160 - 190 bar (2320- 2756 lbf/in 2)

Carrier Pressure relief - minimum Measured operating pressure plus 60 bar

Carrier Pressure relief - maximum 210 bar (3046 lbf/in 2)

Oil supply 140 - 190 l/min (36.9 - 50.1 gal/min)

Maximum return line back pressure 10 bar (145 lbf/in2)

Input power (max) 48 kW

Port adaptors - Hammermaster/connecting hoses

Pressure line 1 in BSP (male)
Return line 1 in BSP (male)

Oil
Temperature range - 20 °C + 80 °C (- 4 °F + 176 °F)
Viscosity 1000 - 15 cSt.

Carrier weight 21 - 32 tonne (46297 - 70560 lb)

Tools
Shank diameter (new) 135 mm (5.31 in)
Shank diameter (minimum allowable) 130 mm (5.12 in)

Bushings
Diameter (new) 135 mm (5.31 in)
Diameter (maximum allowable) 140 mm (5.51 in)

HP Accumulator charging pressure 55-60 bar (780-850 lbf/in2)

Piston Accumulator Pressure 10-16 bar (145-230 lbf/in2) Check with no load on tool.

Noise 90 db (A)

JCB Nitrogen Kit part number 998/11323

332/A3098-1
10 GENERAL DESCRIPTION 10

Power Cell

Tool Retaining
Pin

Tool

332/A3098-1
11 SERVICE 11

Dismantling 3 Lay the power cell on wooden supports of equal size

to ensure that it is horizontal.
Safety First

!WARNING
Maintenance work must only be done by competent
personnel.
A-3-1-1

!WARNING
Equipment Condition
Defective equipment can injure you or others. Do not
operate equipment which is defective or has missing
parts.

Make sure the maintenance procedures in this manual

are completed before using the equipment.
A-1-4-1

!WARNING 4 Ensure once again that all gas is removed from the
Before doing any routine maintenance work on the piston accumulator.
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.

!WARNING
The accumulator(s) in the hammermaster are
pressurised even when there is no hydraulic pressure
to the breaker. Never tamper with an accumulator.
Attempting to dismantle an accumulator without first
releasing the pressure can cause injury or death. Such
work should only be carried out by qualified servicing
personnel who have studied the relevant Service
Manual.
B-1-3-7
5 Mark the tie rod, the nut and the front head retaining
nut for rebuilding identification purposes. i.e. use the
same tie rod and nut in the same position on the front
1 Ensure that all gas pressure is released from the head.
Hammermasters before commencing any service or
maintenance work on the Hammermaster.

2 It is assumed that the power cell has ben removed

from the housing or side plates.(see Operator
Manual)

332/A3098-1
12
SERVICE 12

8 Lift the piston clear of the cylinder using an eyebolt

5 Remove the tie rod nuts from the power cell. and lifting vertically using the hoist or chain block.

6 Remove the head cap using a hoist or chain block.

9 Remove the tie rods from the front head.Using a

suitable spanner on the ‘flat’ section of the tie rod
remove the tie rods from from the front head and the
front head retaining nuts (A).
7 Remove the cylinder using a hoist or chain block, moving
it in the direction shown by the arrows in the illustrations.

10 Remove and discard all seals and O rings.

332/A3098-1
13 SERVICE 13

Inspection of Parts 3 Tool Retaining Pins: If the tool retaining pins become
damaged and after 100-150 hours of operation it is
1 Control Valve: Inspect the valve for scars, seizure or recommended that the connecting faces of the pins are
scuffing. All marks however small must be removed reversed.
using a fine oil stone or fine emery paper. The
corresponding marks on the valve bush must also be
removed in the same manner.

If the seizure or scratch is excessive then a new

control valve assembly must be used immediately.
4 Wear Limit of Tool and Front Bush: When the limit
becomes too large replace tool and bush to prevent
2 The lower end of the piston (in contact with the tool) damage to the piston and cylinder.
must be checked at regular intervals for deformation.
Check the piston for seizure marks and scuffing,
again, remove with oilstone or fine emery paoer.
Corresponding marks on the cylinder must also be
removed in the same manner. Replace if the damage
is too great.

Wear Limits
HM 380 6mm 0.23in

HM 480 8mm 0.35in

HM 1180 8mm 0.35in

HM 2180 10mm 0.394in

Wearing Parts

1 Tools
2 Front Cover and Bush
3 Tool Retaining Pins
4 Hydraulic Seals
5 Tie rods
6 Hydraulic Hoses

332/A3098-1
14 SERVICE
Removal of Parts & Deburring
!WARNING
Wear Safety Approved Eye Protection.
Remove the Worn/damaged front cover and bush.
Choose a removal method from the three examples given
below.
1 Remove the bush(s) using oxy-arc cutting. This will
require a highly skilled worker to prevent damage to
the front cover.
2 Press out the bushes after welding the removal plate
into front bush as shown in the illustration. This task
can only be carried out in a well equipped workshop
with an hydraulic press of at least 200 tonnes
capacity.
3 If oxy-arc cutting and a hydraulic press are not
available the following procedure is possible.
332/A3098-1
14
Apply a thick coating of axial or radial welded beads
inside the worn bush, as illustrated, using an electrode
welder. Upon cooling the bush contracts and loosens in
its seat.
Before refitting th new bush to the front cover, heat the
front cover to to make oversize. The alternative is to cool
the bush using liquid nitrogen to reduce the bush size.
!WARNING
Do not allow over heating of the front cover, it
may weaken it.
Deburring
When correcting faults on sliding surfaces ensure that the
finished surfaces are as smooth as possible. Use an
oilstone, emery paper and flexiable hone. Always bear in
mind that overworking can cause damage.
Type of Tool Grain Size
Rough Finish Fine Finish
Oilstone Rough/Medium Grain Fine Grain
Emery Paper #100,#160,#240 #400,#600
In both cases polish perpendicular to the sliding direction.
1 Cylinder Bush: When using the buffing grindstone
apply the stone correctly to the circumference. If the
stone is forced straight ahead circularity will be
affected. (see Illustration) Wash parts after finishing.
15 SERVICE 15

Removal of Parts & Deburring (cont.)

2 Cylinder: Faults on the sliding surface may cause

malfunctioning and leakage of the cylinder and in the
worse cases disable the breaker if not remedied. Correct
the faults at an early stage using an oilstone and emery
paper.

Take care when using the Buffer Grinder.

Kind of Fault Condition Remedy

Vertical
Scratch

If burrs stick out above labyrinth grooves,

A stripped fault running in the sliding remove burrs and correct vertical faults
direction of the blow piston. withoilstone and/or emery paper.

Galling

A localized fault that is wider than the Finish Galling with an oilstone till no step
vertical scratch and is caused by exists on the outer surface and then finish
sliding motion. with fine emery paper.

continued

332/A3098-1
16 SERVICE 16

Removal of Parts & Deburring (cont.)

Chipping

Corner of sliding section is chipped. Finish the edge produced by polishing

smoothly with an oilstone.

Vermin

A vermin-like fault by cavitations located at A vermin causes galling if left uncorrected.

the corner of a sliding part. Remove it with an air grinder and finish it
smoothly with an oilstone.

Piston

Correct faults at an early stage using

an oilstone and emery paper.

Fault Condition Remedy

Vertical
Scratch

Striped scratches caused by sliding motion of Remove burrs on the surface by polishing in
contaminated oil. the circumferential direction.

332/A3098-1
17 SERVICE 17

Removal of Parts & Deburring (cont.)

Scratch in
labyrinth
grooves

Remove burrs sticking above grooves, finish

Correct scratches at an early stage as
edges, remedy vertical scratches.
scratches in this area may develop into a
total failure of the cylinder.

Repairing a
vertical
scratch
and/or
rust pit
Using a polishing machine, remove
burrs on surface by polishing in
circumferential direction for max. 0.05 mm
less of normal diameter. If scratches and/or
rust pit still remain replace piston by new one.

Damage on the Piston/Tool Contact Surface

Damage on the piston/tool contact surface has adverse effect on the tool. Correct it an early stage or replace the piston with
a new one.

Depression

If the piston contact surface has a depression of 2.0 mm or more in depth, replace with a new one. If the contact surface has
a step of less than 1.0mm in depth, smooth the area.

332/A3098-1
 18 SERVICE 18

Fitting the New Bush

Assembling the Hammermaster
1 Before fitting the new bush to the front head, heat
1 Once the cylinder bush and cylinder have been cleaned the front head or supercool the new bush in liquid
thoroughly the seals should be lightly coated with hydraulic nitrogen (N2) to make undersize for fitting. Do not
oil before fitting. overheat the front head as this can weaken it.

2 Keep the contact face of the front head clean

2 Remove the rubber plugs and bush retaining pins for the when fittingthe new bush.
tool from the front head.
3 Replace the bush retaining pins and rubber
plugs.

!WARNING
The accumulator(s) in the hammermaster are
pressurised even when there is no hydraulic pressure to
the breaker. Never tamper with an accumulator.
Attempting to dismantle an accumulator without first
releasing the pressure can cause injury or death. Such
work should only be carried out by qualified servicing
personnel who have studied the relevant Service Manual.
B-1-3-7

332/A3098-1
19 SERVICE 19

4 Replace the tie rods in the front head. Using a
suitable spanner on the ‘flat’ section of the tie rod
remove the tie rods from from the front head and the
front head retaining nuts (A) as previously marked up
( see page 11).
8 Connect the cylinder front head and head cap with
the tie rods. Tighten the tie rod nuts to their specified
torque (see Torque Table).

HM 2180 - 1180
A

5 Replace the seals in the cylinder and bush.

6 Replace the piston into the cylinder after thoroughly

lubricating both piston and cylinder with new clean
hydraulic oil.

9 Fill the cylinder with hydraulic oil via the ports on the
cylinder.

10 Tighten the hose connectors into the ports on the

cylinder (see Torque Table)

11 Fit the gas charging valve and tighten to specified

torque (see Torque Table)

12 Add hydraulic oil to the inside of the head cap. The

following quantities of should be used:

7 Replace cylinder bush onto the piston using a rubber

hammer. HM 380 80cc

HM 480 150cc

HM 1180 230cc

HM 2180 340cc

13 Charge the piston accumulator (see Technical

Specification and Charging Accumulator)

332/A3098-1
20 SERVICE 20

14 Refit the assembled power cell into the housing (HM

2180 and HM 1180) or fit the sideplates to the HM
380 and HM 480. A crane or hoist should be used for
this operation.

15 For replacement of the tool see Operator Manual.

16 Remember these Hammermasters are heavy. Use the

correct lifting points and hoists.

332/A3098-1
21
Charging the Accumulators
!WARNING
The accumulator(s) in the hammermaster are pressurised
even when there is no hydraulic pressure to the breaker.
Never tamper with an accumulator. Attempting to
dismantle an accumulator without first releasing the
pressure can cause injury or death. Such work should only
be carried out by qualified servicing personnel who have
studied the relevant Service Manual.
B-1-3-7
Charge the Nitrogen Gas into the Piston
Accumulator
Note: Ensure that no one is standing in the immediate area
of the working tool.
1 Remove the valve cap of the charging valve.
2 Fit the charging adaptor into the inlet of the charging
valve.
Note: If the adaptor is already connected to the gas hose,
the adaptor will not fit into the inlet
3 Connect the hose to the charging adaptor, Hand
Tight Only.
SERVICE 21
Note: JCB does not supply Nitrogen Gas. Contact your
local JCB Distributor.
Your attention is drawn to the JCB Gas Charging Kit
Manual 9814/0579-01 which details the necessary tools
required to charge the Accumulators correctly and safely.
4 Check that the valves A,B and the gas bottle valve C
are closed.
B
C
A
5 Open the valve of the gas bottle.
6 Turn the handle slowly clockwise, as shown, until the
pressure reaches 14kg/cm2( 200psi ). Turn the handle
anti-clockwise to close. If the increase is not sufficient
then turn clockwise again. Repeat the action until the
pressure is as required ( see Technical
Specification).
7 Disconnect the hose from the adaptor.
332/A3098-1
22 SERVICE 22

8 Disconnect the adaptor from the charging valve 3 Connect the charging adaptor into the inlet of the
charging valve.

Note: If the adaptor is already connected to the gas hose,

the adaptor will not fit into the inlet.

9 Replace the cap into the charging valve. ( see

Torque Table)

4 Check that valves A,B,C and the gas bottle valve D

are closed.

D
Charge the Accumulator
A B
1 Remove the charging valve cap.
5 Connect the hose to the adaptor. Hand Tight Only.

2 Remove the needle valve cap.

6 Turn the needle valve anti-clockwise.

332/A3098-1
23 SERVICE 23

7 Open the valve of the gas bottle D and charge the 11 Remove the charging adaptor from the inlet
accumulator to 65kg/cm2( 925 psi ). Close the valve valve.
of the gas bottle.

12 Refit the inlet valve cap.

8 Control the gas pressure to 55-60kg/cm2 (782-839
psi ) using drain valve C ( see item 4 ). Remember
the air temperature when charging. High air
temperature can increase bottle pressure.

C
13 Refit the needle valve cap.

9 Close the needle valve, turning clockwise. (See

Torque Table)

Note: See Torque Table for all closing torques.

10 Disconnect the hose from the adaptor.

332/A3098-1
24 SERVICE 24

Checking Acculumator Nitrogen gas

pressure

1 Remove the charging valve cap. 5 Connect the hose to the adaptor. Hand Tight Only.

2 Remove the needle valve cap. 6 Turn the needle valve anti-clockwise.

3 Fit the charging adaptor into the charging valve 7 The pressure will be shown on both gauges. Check
inlet. Hand Tight Only. the Technical Specifications for correct pressure.

Note: If the adaptor is already connected to the gas

hose, the adaptor will not fit into the inlet.

8 Close the needle valve and remove all hoses and

adaptor. (See Torque Table).

4 Fit the needle valve cap to the charging valve as

shown, in place of the connection to the gas
bottle.

332/A3098-1
25 SERVICE 25

Checking Acculumator Nitrogen gas

pressure (cont.)
9 Disconnect the hose from the adaptor.

10 Remove the charging adaptor from the inlet valve.

11 Refit the inlet valve cap ( see Torque Tables ).

12 Refit the needle valve cap ( see Torque Table ).

332/A3098-1
 26 SERVICE 26

TORQUE TABLES

HM 380 Nm (lbf.ft) HM 480 Nm (lbf.ft)

Tie Rods 441 - 490 (325 - 361) 882 - 931 (651 - 687)
Accumulator Filling Valve Cap
(accumulator cover on top)
49 (36) 49(36)
Accumulator mounting screws
(accumulator body)
395(291) 395(291)

Accumulator Cover Screws

245(181) 245(181)
Check valve cover screws
(Cap gas charging valve on the Backhead)
49(36) 49(36)

Hanger bracket retaining bolts

410(302) 470(347)

HM 1180 Nm (lbf.ft) HM 2180 Nm (lbf.ft)

Tie Rods 1862 - 1960 (1373 - 1446) 3136 - 3234 (2313 - 2385)
Accumulator Filling Valve Cap
(accumulator cover on top)
49 (36) 49 (36)
Accumulator mounting screws
(accumulator body)
833 (614) 833 (614)

Accumulator Cover Screws 343 (253) 392 (289)

Check valve cover screws
(Cap gas charging valve on the Backhead)
83 (60) 83 (60)

Hanger bracket retaining bolts 470 (347) 470 (347)

332/A3098-1
27 SERVICE 27

Automatic Greasing System

(HM2180 and HM1180 only)

Hammermaster breakers are subject to loads whens operating

in the harsh conditions for which they are designed. The
constant impact shock, high reciprocating speeds and the
dusty (or muddy) conditions demand the highest order of
lubrication of wear parts. The intermittent manual greasing
normally used can make this impossible to achieve.

Automatic greasing systems are available to supply a constant

flow of lubrication to the critical points on the hammers, such
as the lower tool bushing and the tool shank, whilst the
hammer is operating.

JCB Autogrease System

This system is offered as a self-contained alternative to

manual greasing.

The essential features of the system are as follows:-

(see illustrations X & Y opposite)

1 Compact self priming grease pumping unit. A

2 Unit mounted directly on the breaker housing.

3 Greasing unit hose B protected inside the breaker

housing.

4 No tools required to change the grease cartridge C

(Hand tight screw fit)

see following pages for further details of the system.

332/A3098-1
28 SERVICE 28

Self Contained Re-Chargeable Greasing Specification

System
Output Pressure Approx. 10 kg
This System is charged with grease before commencing
work and is replenished as required during the working Cylinder Capacity 400 ml
period.
Weight (without grease) 5.5 kg
To charge the system the grease cartridge is removed from
the unit, the charging handle is freedand the injection port Output Port Pf1/4”
inserted into the grease (see 1). Pulling up the handle
allows grease to be drawn into the cartridge and the Grease Type NLGI No.2 (JCB Extreme
quanity is controlled by the space available. Once filled the Performance Hammer Grease)
handle is locked by turning it clockwise and the cartridge is
returned to the body. The grease is releasd by unlocking
the handle and pressing the handle downwards. This Available Temperature Range -10 deg C to -50 deg C
amount can be varied by turning the adjuster screw,
clockwise to decrease the amount and anticlockwise to
increase the amount. (See item 2 on next page)

1 Insert injector into the grease. 2 Pull up the handle to draw grease
into the cartridge.

3 Push down handle to compress the 4 When the cartridge is full, fasten the
grease. handle by turning it clockwise.

Repeat 2 & 3

332/A3098-1
29 SERVICE 29

Self Contained Re-Chargeable Greasing System (cont.)

332/A3098-1
30 SERVICE 30

Greaser Parts List

Item Description Size

1 BODY

2 “COMPRESS
CYLINDER” F79x265L

3 LOCK SEAL F60

4 HANDLE

5 PLUG PT3/8”

6 NIPPLE M20-PT1/4

7 SPRING F17x30L

8 BALL F14

9 NIPPLE PT1/8”

10 ADJUSTER M8

11 NUT M8

12 BALL F35

13 SPRING F32x55L

14 COVER

15 BOLT M6

16 NIPPLE PT1/4”

332/A3098-1
31 SPECIFICATION 31

Carrier Requirements
HM 380 HM 480
Carrier weight limits - tonne 6- 12 12 - 18
Carrier hydraulic supply ARV limits - bar 175 (JCB Machines only) 175 (JCB Machines only)

Carrier hydraulic supply flow limits - litres/min 40- 80 45 - 90

Note: Ensure that the carrier cannot exceed 100 l/min. This can be done by fitting a flow restriction valve or marking
the engine speed dial. Excess flow can cause permanent damage to the Hammermaster.

Additionally during Hammermaster operation the carrier’s hydraulic circuit must be capable of maintaining the oil
temperature between the limits - 20 °C + 80 °C (- 4 °F + 176 °F).

Note: Faulty installation may cause premature and possible permanent damage to the Hammermaster. For this reason, we
strongly recommend that installation is carried out by your JCB Distributor

332/A2977-1
32 SPECIFICATION 32

Carrier Requirements
HM 2180 HM 1180
Carrier weight limits - tonne 21- 32 12 - 20

Carrier hydraulic supply ARV limits - bar 210 (JCB Machines only) 210 (JCB Machines only)

Carrier hydraulic supply flow limits - litres/min 120 - 200 100 - 150

Note: Ensure that the carrier cannot exceed 200 l/min. This can be done by fitting a flow restriction valve or marking
the engine speed dial. Excess flow can cause permanent damage to the Hammermaster.

Additionally during Hammermaster operation the carrier’s hydraulic circuit must be capable of maintaining the oil
temperature between the limits - 20 °C + 80 °C (- 4 °F + 176 °F).

Note: Faulty installation may cause premature and possible permanent damage to the Hammermaster. For this reason, we
strongly recommend that installation is carried out by your JCB Distributor

9814/0559-3
40 PARTS LIST 40

HM2180 & HM1180 - Power Cell

Spare Parts List - Wear Parts

Part Qty.

Stopper Pin 2

Rubber Plug 2

Chisel Pin 1

Grease Nipple 1

Hollow Plug 1

T/Bolt Set 1

Diaphragm 1

Seal Kit 1

Gas Valve Set 1

332/A3098-1
41 PARTS LIST 41

Parts Illustrations - Power Cell - HM 2180& HM1180

332/A3098-1
42 PARTS LIST 42

Power Cell - Parts List - HM 2180 & HM 1180

ITEM No DESCRIPTION QTY

01 CYLINDER 1

02 DUST SEAL 1

03 U-PACKING 1

04 BUFFER RING 1

05 HOSE ADAPTOR 2

06 UNION CAP 2

07 O-RING 3

08 PLUG 1

09 PLUG 4

10 O-RING 5

11 PLUG 6

12 O-RING 6

13 O-RING 1

14 O-RING 1

15 HOLDING PIN 2

16 GREASE NIPPLE 1

17 PISTON 1

18 CYLINDER BUSH 1

19 GAS SEAL 1

20 STEP SEAL 2

21 O-RING 3

- 13,22,23,24,25 VALVE SET 1 (set)

22 VALVE 1

23 VALVE BUSH 1

24 VALVE CAP 1

25 O-RING 1

- 14,26,27,28,29 ADJUSTER SET 1(set)

26 ADJUSTER 1

27 O-RING 1

28 ADJUSTER HOLDER 1

29 ADJUSTER NUT 1

30 FRONT HEAD 1

31 ROUND BUSH 1

32 FRONT COVER 1

332/A3098-1
43 PARTS LIST 43

Power Cell - Parts List HM 2180 & HM1180 (cont.)

ITEM No DESCRIPTION Qty.

33 STOPPER PIN 4

34 RUBBER PLUG 4

35 CHISEL PIN 2

36 HOLLOW PLUG 1

37 AIR PLUG ASS`Y 1

38 O-RING 1

- 39,40,41,42 TIE ROD SET 4(Set)

39 TIE ROD 4

40 TIE ROD WASHER 4

41 TIE ROD TOP NUT 4

42 TIE ROD BOTTOM NUT 4

43 HAMMER TOOL 1

43-1 MOIL

43-2 PYRAMID

43-3 CHISEL

43-4 CHISEL TRANSVERSE

43-5 BLUNT

44 BACK HEAD 1

- 45,46,47,48 GAS VALVE SET 1(set)

45 GAS VALVE 1

46 O-RING 2

47 GAS VALVE CAP 2

48 O-RING 2

- 10,47,48,49,50,51,52,53,54,55,56,57 ACCUMULATOR SET 1(set)

58,59,60,61,62

49 ACC" BODY 1

50 ACC" COVER 1

51 FACE SEAL 1

52 REBBEDLOCK WASHER 4

53 DIAPHRAGM 1

- 54,55,56 POPPET VALVE SET 1(set)

54 POPPET VALVE(3set) 1

55 POPPET VALVE NUT 1

56 KNOCK PIN 1

332/A3098-1
44 PARTS LIST 44

Parts List - Power Cell - HM 2180 & 1180 (cont.)

ITEM No DESCRIPTION QTY

10,57,58,59 NEEDLE PIN SET 1(set)

57 NEEDLE PIN 1

58 O-RING 1

59 NEEDLE CAP 1

60 SOCKET BOLT 12

61 SOCKET BOLT 4

62 HELICOIL INSERT 4

- SEAL KIT, COMPLETE 1(set)

332/A3098-1
45 PARTS LIST 45

Parts Illustration - Housing - HM 2180 & HM 1180

332/A3098-1
46 PARTS LIST 46

Parts List - Housing - HM2180 & HM1180

ITEM No DESCRIPTION QTY

- MAIN BODY ASSEMBLY

1 BRACKET 1

2 BOTTOM DAMPER 1

3 UPPER DAMPER 1

4 ADAPTER PLATE 1

5 HEX. HEAD BOLT 2

6 HEX NUT 4

7 MC PAD 5

8 MC PAD 2

9 MC PAD 2

10 O-RING 18

11 HEAD PLATE 1

12 HEAD DAMPER 2

13 RUBBER COVER 4

14 RUBBER COVER 4

15 AUTO GREASE COVER 1

16 MC COVER 1

17 HOSE COVER 2

18 FLAT HEAD SOCKET SCREWS 4

19 SIDE HOSE COVER 2

20 SOCKET BOLT 4

21 WASHER 4

22 COMPLETE AUTO GREASER 1

23 BOLT 4

24 WASHER 4

25 GREASE HOSE 1

332/A3098-1
47 PARTS LIST 47

Parts List for HM 380 Sideplates

Item No. Description Qty.

1 Left Bracket Assembly 1

2 Right Bracket Assembly 1

3 Hexagon Head Bolt 5

4 Space Tube 1

5 Spring Washer 5

6 Cap Nut 5

7 Hose 2
332/A3098-1
48 PARTS LIST 48

Parts List for HM 480 Sideplates

Item No. Description Qty.

1 Side Plate Set 1

2 Bottom Holder 2

3 Upper Holder 2

4 Hexagon Head Bolt 6

5 Spring Bolt 6

6 Cap Nut 6

7 Hose 2

332/A3098-1
49 PARTS LIST 49

Parts Illustration - Power Cell - HM 380

332/A3098-1
50 PARTS LIST 50

Parts List - Power Cell - HM 380

Item No. Description Q’ty
1 Cylinder 1
2 Dust Seal 1
3 U-Packing 1
4 Hose Adapter 2
5 Union Cap 2
6 O- ring 6
7 Plug 2
9 O- ring 1
10 Plug 6
11 O- ring 6
12 Piston 1
13 Cylinder Bush 1
14 Gas Seal 1
15 Step Seal 2
16 O- ring 3
- Valve Set (17,18,19,20,21.) 1 (set)
17 Valve 1
18 Valve Bush 1
19 Valve Cap 1
20 O- ring 1
21 O- ring 1
26 Front Head 1
27 Round Bush 1
28 Front Cover 1
29 Stopper Pin 2
30 Rubber Plug 3
31 Grease Nipple 1
32 Chisel Pin 2
33 Chisel Stop Pin 1
34 Spring 1
35 Spring Pin 1
36 Air Plug Assy. 1
- Tie Rod Set (37,38,39.) 4 (set)
37 Tie Rod 4
38 Washer 4
39 Nut 4

332/A3098-1
51 PARTS LIST 51

Parts List - Power Cell - HM 380 (cont.)

Item No. Description Qty.
40 Hammer Tool 1
40-1 Moil
40-2 Pyramid
40-3 Chisel
40-4 Chisel Transverse
40-5 Blunt
41 Head Cap 1
- Gas Valve Set (6,42,43,44.) 2(set)
42 Gas Valve 2
43 Gas Valve Cap 2
44 O-ring 2
- Accumulator Set 1(set)

45 Accumulator Cover 1
46 Accumulator Body 1
47 Diaphragm 1
48 Diaphragm Ring 1
49 O-ring 1
50 Back Up Ring 1
51 Spring Washer 4
52 Socket Bolt 4
53 Socket Bolt 8
- Seal Kit, complete 1 (set)

332/A3098-1
52 PARTS LIST 52

Parts Illustration - Power Cell - HM 480

332/A3098-1
53 PARTS LIST 53

Parts List - Power Cell - HM480

Item No. Description Qty.
1 Cylinder 1
2 Dust Seal 1
3 U-Packing 1
4 Buffering 1
5 Hose Adaptor 2
6 Union Cap 2
7 O-ring 3
8 RO Plug 1
9 O-ring 3
10 RO Plug 8
11 O-ring 8
12 Piston 1
13 Cylinder Bush 1
14 Gas Seal 1
15 Step Seal 2
16 O-ring 3
- Valve Set (17,18,19,20,55.) 1 (set)
17 Valve 1
18 Valve Bush 1
19 Valve Cap 1
20 O-ring 1
- Adjuster Set (7,21,22,23,24) 1 (set)
21 Adjuster 1
22 O-ring 1
23 Adjuster Holder 1
24 Adjuster Nut 1
25 Front Head 1
26 Round Head 1
27 Front Cover 1
28 Stopper Pin 2
29 Rubber Plug 3
30 Grease Nipple 1
31 Chisel Pin 2
32 Chisel Stop Pin 1
33 Spring 1
34 Spring Pin 1
35 Air Plug Ass’y 1
36 O-ring 1

332/A3098-1
54 PARTS LIST 54

Parts List - Power Cell - HM 480 (cont.)

Item No. Description Qty.
- Through Bolt Set (37,38,39.) 4 (set)
37 Through Bolt 4
38 Through Washer 4
39 Through Bolt Top Nut 4
40 Hammer Tool 1
40-1 Conical Point
40-2 Moil Point
40-3 Crosscut (Wedge H)
40-4 In-Line (Wedge V)
40-5 Flat End
41 Head Cap 1
- Gas Valve Set (9,42,43,44.) 2 (set)
42 Gas Valve 2
43 Gas Valve Cap 2
44 O-ring 2
45 Holding Pin 2
- Accumulator Set (9,42,43,44,45,46,47,48,49,50,51,52 1 (set)
53,54.)
46 Accumulator Cover 1
47 Accumulator Body 1
48 Diaphragm 1
49 Diaphragm Ring 1
50 O-ring 1
51 Backup Ring 1
52 Spring Washer 4
53 Socket Bolt 4
54 Socket Bolt 8
55 O-ring 1
- Seal Kit, complete 1 (set)

332/A3098-1
55 PARTS LIST 55

HM380 & HM480 - Power Cell

Spare Parts List - Wear Parts

Part Qty.

Stopper Pin 2

Rubber Plug 2

Chisel Pin 1

Grease Nipple 2

Hollow Plug 1

T/Bolt Set 1

Diaphragm 1

Seal Kit 1

Gas Valve Set 1

332/A3098-1