Complete workshop & service manual with electrical wiring diagrams for JCB Hammermaster, Rockbreaker, HM Range Medium Breaker, Large Hydraulic Breaker. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Hammermaster, Rockbreakers, HM Range Medium, Large Hydraulic Breakers service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-1300 - JCB Hammermaster, Rockbreakers Service Manual.pdf
9803-1420 - JCB HM Range Medium, Large Hydraulic Breakers Service Manual.pdf

EXCERPT:
Contents Page No.
Hammermaster Identification 1 - 1
Torque Settings
Hammermaster 360 Range 2 - 1
Hammermaster 460-110 2 - 3
Hammermaster 560 2 - 4
Hammermaster 660 2 - 5
Hammermaster 760 2 - 6
Hammermaster 860 2 - 7
Hammermaster 960 2 - 8
Hammermaster 160 Range 2 - 9
Hammermaster 260 Range 2 - 10
Hammermaster 570 2 - 11
Hammermaster 670 2 - 12
Hammermaster 770 2 - 13
Hammermaster 1050, 1150 2 - 14
Hammermaster 1350, 1450 2 - 15
Hammermaster 1750 2 - 16
Hammermaster 2350/2950/3850/3950 2 - 17
Hammermaster 550 2 - 18
Hammermaster 850 2 - 19
Service Tools 3 - 1
Nord-Lock Washers 3 - 1
Accumulator Charging 3 - 2
Safety Notices 4 - 1
General Safety 5 - 1
Operating Safety 6 - 1
Maintenance Safety 7 - 1
Safety Decals 8 - 1
Lubricants - Health and Safety 9 - 1
Note: Hammermaster 70 - All Service Information relating to this hammer is contained in Section 13. Safety requirements are retained in this section.
Note: Hammermaster 100 and Hammermaster 115 - All Service
Information relating to these hammers is contained in Section 20.
Safety requirements are retained in this section.
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Contents Page No.
i i
Medium Breakers
Introduction ............1
Safety ....1
General Information .....1
Workshop Standards ..............1
Spare Parts .......1
Service Personnel .......1
Using this Manual ........2
Standard Symbols ............3
Service Tools .........5
Charging Equipment .......10
Medium Breakers - HM165Q, 265Q, 385Q, 495Q
Dismantling .......... 11
Assembly .............18
Field Bushing Exchange ............23
Charging the Accumulator .........25
Hanger Brackets .............27
Exploded Views ..............28
Operating Principles .......32
Stage 1 - Start Up ......32
Stage 2 - Return Stroke ........32
Stage 3 - Power Stroke .........33
Stage 4 - End of Power Stroke ........33
Medium Breakers - HM386Q
Special Tools .......34
Dismantling ..........38
Assembly .............45
Operating Principles .......54
Stage 1 ...........54
Stage 2 ...........54
Stage 3 ...........55
Stage 4 ...........55
Stage 5 ...........56
Medium Breakers
Technical Specifications ............57
Nitrogen Adaptor Reference Chart .......58
Tool Part Numbers ..........63
Breaker Part Number Matrix ......64
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Chapter Title Page
Introduction
1 General 1
1.1 Explanation of the symbols in the repair manual 1
Safety
2 Operational safety 2
2.1 General 2
2.2 Accident prevention regulations 2
2.3 Safety Notices 3
Tools
3 Tools 5
3.1 General tools 5
3.2 Service box 6
3.3 Special accessories 7
3.3.1 Accumulator charging device 7
3.3.2 Power wrench 8
3.3.3 HeliCoil-tools 8
3.3.4 Fitting aid for piston 9
3.3.5 Press-out aid for wear bushes 9
3.4 Consumables 10
Technical Specifications
4 Technical Specifications 11
4.1 Breaker Specifications 11
4.2 Working Pressure/Required Flow/Engine RPM 16
Dismantling
5 Dismantling the Hydraulic Breaker 21
5.1 Fitting/Removing the Tool 21
5.2 Removing the Power Cell from the Hammer Housing 22
5.3 Removing the High-Pressure Accumulator 23
5.4 Removing the Control System 24
5.5 Removing the Control Slide Valve 24
5.6 Removing the Frequency Switching System 25
5.7 Removing the Cylinder Cover 26
5.8 Removing the Piston and sealing Bush 28
5.9 Removing the Cylinder 28
5.10 Removing the Locking Pins for the Retainer Bars in the Lower Breaker Part 29
5.11 Removing the Locking Bushes 29
Checking
6 Checking the Hammer Housing 30
6.1 Checking for Cracks and Indentations 30
6.2 Wear to the Bottom Plate 30
6.3 Checking the Elastic Pad 31
6.4 Checking the Damping Elements 31
6.5 Checking the Guide Plates 32
6.6 Checking the Tool for Wear 33
Assembling
7 Assembling the Hydraulic Hammer 34
7.1 Tightening Torques for Screws and Screw Couplings on the JCB HM 860Q 34
7.2 Tightening Torques for Screws and Screw Couplings on the JCB HM 1260Q 35
7.3 Tightening Torques for Screws and Screw Couplings on the JCB HM 1560Q 36
7.4 Tightening Torques for Screws and Screw Couplings on the JCB HM 1760Q 37
7.5 Tightening Torques for Screws and Screw Couplings on the JCB HM 2460Q 38
7.6 Tightening Torques for Screws and Screw Couplings on the JCB HM 3060Q and JCB HM
4160Q
39
7.7 Fitting the Cylinder 40
7.8 Fitting the Piston and sealing Bush 40
7.9 Fitting the Cylinder Cover 41
7.10 Fitting the Frequency Switching System 43
7.11 Fitting the Control Slide Valve 44
7.12 Fitting the Control System 44
7.13 Fitting the High-Pressure Accumulator 45
7.14 Checking Pressure in piston Accumulator and Refilling if Required 46
7.15 Fitting the Power Cell into the Hammer Housing 48
7.16 Connecting the JCB AUTOGREASE 49
7.17 Fitting the Tool 50
Changing Seals
8 Changing the Seals 51
8.1 Changing the Cylinder Seals 51
8.2 Changing the Seals between Cylinder and Cylinder Cover 53
8.3 Changing the Seals on the Control System 53
8.4 Changing the Seals on the High Pressure Accumulator 54
8.5 Changing the seals on the Sealing Bush 54
Repair Work
9 Repair Work 55
9.1 Changing the Expansion Bolts on the High-Pressure Accumulator 55
9.2 Changing the High-Pressure Accumulator 55
9.3 Changing the Tie Rods 56
9.4 Removing Scores from Control slide Valve and Bore 57
9.5 Removing Scores on Piston and Cylinder Bore 57
9.6 Changing the Wear Bushes 58
9.7 Replacing the Complete Housing 60
9.8 Replacing Guide Plates and Damping Elements in Housing 60
9.9 Repairing Cracked Welds 61
9.10 Replacing the Bottom Plate on the Housing 61
9.11 Reworking the Retainer Pins for the Damping Elements 62
9.12 Weld Seam Preparation 62
9.13 Preheating Temperature 62
9.14 Fillers 62
9.15 Post-treatment of Welds 62
Spares List
10 Spares List 63
10.1 Percussion Unit 63
10.2 Noise Damping 64
10.3 JCB AUTOGREASE 65
Appendices
1 Breaker Operating Principles 67
2 JCB Autogrease Operating Principles 75
Nitrogen Adaptor Reference Chart
11 Nitrogen Adaptor Reference Chart 90
Tool Part Numbers
12 Tool Part Numbers 92
Breaker Part Number Matrix
13 Breaker Part Number Matrix 93
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