Download Operator’s Manual For JCB HM860Q, HM1260Q, HM1560Q, HM1760Q, HM2460Q,
HM3060Q, HM4160Q LARGE HYDRAULIC BREAKERS.
Part No. – 9814/0526 ISSUE 3 FEB 2006
This operator’s manual is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance and technical data. Read this manual from the front to the back before you use the machine for the first time, even if you have used machines of a similar / same type before as the technical specification, systems and controls of the machine may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.. With this in-depth & highly detailed manual you will be able to operate on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your bussiness.
ENGLISH PAGES 1- 55
PAGES FRANÇAISES 1- 55F
DEUTSCHE SEITEN 1- 55G
PAGINAS EN ESPAŃOL 1- 55S
TESTO IN ITALIANO 1- 55L
PÁGINAS EM PORTUGUĘS 1- 55P
STRANICE NA HRVATSKOM 1- 67HR
Models Covered:
HM860Q, HM1260Q, HM1560Q, HM1760Q, HM2460Q,
HM3060Q, HM4160Q Serial Numbers 1095001 onwards
This manual is INSTANT DOWNLOAD. It means no shipping cost or waiting for getting a CD package for several days. You will receive this manual today via instant download on completion of payment via our secure payment processor.
Manual Contents:
1 About this Manual……………………………………………………………………………………………………..1
2 Safety Notices …………………………………………………………………………………………………………..2
2.1 General Safety…………………………………………………………………………………………………………4
2.2 Safety Decals ………………………………………………………………………………………………………….6
3 Technical Specifications ……………………………………………………………………………………………..9
3.1 Breaker Specification ……………………………………………………………………………………………….9
3.2 Working Pressure/Required Flow/Engine RPM…………………………………………………………..14
4 Main Components ……………………………………………………………………………………………………….19
5 Installation ……………………………………………………………………………………………………20
5.1 Consumables ……………………………………………………………………………………………………….20
5.1.1 Mineral hydraulic oil ……………………………………………………………………………………………20
5.1.2 Non-mineral hydraulic oil …………………………………………………………………………………….20
5.1.3 Grease …………………………………………………………………………………………………………………20
4.1.4 Gas ……………………………………………………………………………………………………………………..21
5.2.1 Attaching the hanger bracket to the hydraulic breaker ………………………………………………21
5.2.2 Installing/Removing the Breaker – Preparation ……………………………………………………….22
5.3 Mounting the hydraulic breaker on the excavator mechanical aspects ………………………..23
5.4 Mounting the hydraulic breaker on the excavator ……………………………………………………..24
5.5 Dismounting the hydraulic breaker from the excavator for short or lengthy periods
of non-use ………25
5.5.1 Dismounting from excavator …………………………………………………………………………………..25
5.5.2 Short period of non-use …………………………………………………………………………………………26
5.5.3 Lengthy period of non-use ……………………………………………………………………………………..26
6 Fitting/Removing the Tool …………………………………………………………………………………………27
6.1 Selecting the right tool …………………………………………………………………………………………..27
6.1.1 Tools for hydraulic breakers JCB HM Large Breakers ………………………………………………..27
6.2 Fitting the tool (After breaker delivery to the site) ………………………………………………………28
6.3 Removing the tool …………………………………………………………………………………………………28
7 Installation – Control Settings ……………………………………………………………………………………29
7.1 Carrier machine procedures…………………………………………………………………………………….29
7.2 Breaker flow, pressure and ARV settings…………………………………………………………………..29
8 Operating the Hydraulic Breaker ………………………………………………………………………………..32
8.1 Starting up the hydraulic breaker …………………………………………………………………………….32
8.2 Operation ……………………………………………………………………………………………………………..32
8.3 Angle of attack ……………………………………………………………………………………………………..33
8.4 Breaker rocking …………………………………………………………………………………………………….33
8.5 Never drive the working tool into the ground ……………………………………………………………33
8.6 Never lever with the breaker …………………………………………………………………………………..33
8.7 Never use as a sledgehammer ……………………………………………………………………………….34
8.8 Never use for transport purposes ……………………………………………………………………………34
8.9 Using the hydraulic breaker in or under water …………………………………………………………..34
8.10 Hydraulic breaker used in tunnelling ………………………………………………………………………..35
8.11 Working in high outside temperatures ……………………………………………………………………..35
8.12 Working in low outside temperatures ………………………………………………………………………35
8.13 Operating the breaker with the cylinders fully extended or retracted …………………………..35
9 Maintenance Work to be Performed by the Excavator Driver …………………………………………36
9.1 Automatic lubrication on breakers …………………………………………………………………………..36
9.1.1 Automatic lubrication using JCB AUTOGREASE ………………………………………………………36
9.1.2 Changing the lubricant cartridge …………………………………………………………………………….36
9.1.3 Operating the JCB AUTOGREASE ………………………………………………………………………….37
9.2 Manual lubrication without or upon failure of JCB AUTOGREASE ………………………………38
9.2.1 Filling method for the JCB Extreme Hammer Grease Cartridge ………………………………..38
9.3 Care and maintenance timetable …………………………………………………………………………….39
9.4 Checks required ……………………………………………………………………………………………………40
9.4.1 Checking the working tool for wear …………………………………………………………………………40
9.4.2 Checking the wear bushes and buffer ring ……………………………………………………………….40
9.4.3 Checking the retainer bars for wear …………………………………………………………………………41
9.4.4 Checking the impact face of the percussion piston …………………………………………………..41
9.4.5 Checking the breaker housing for wear and cracks and checking the breaker bracket for
cracks ………..41
9.4.6.1 Screw couplings with tightening torques ……………………………………………………………42
9.4.6.2 Identification of screw couplings ………………………………………………………………………..43
9.4.7 Checking pressure in piston accumulator and refilling if required ……………………………44
9.4.8 Checking that the high pressure accumulator is in perfect working order ………………..46
9.4.9 Checking the hydraulic lines before starting work ………………………………………………….46
9.4.10 Checking the hanger brackets bolts for wear ………………………………………………………..46
9.4.11 Checking and cleaning the hydraulic oil filter ……………………………………………………….46
10 Troubleshooting …………………………………………………….47
10.1 Breaker does not start …………………………………………………………………………………………..47
10.2 Impact rate of hydraulic breaker too low ………………………………………………………………….48
10.3 Impact force too low ……………………………………………………………………………………………..48
10.4 Impact rate too high and impact force too low …………………………………………………………49
10.5 Oil leaks from ports »P« and »T« …………………………………………………………………………….49
10.6 Oil leaks between cylinder cover and cylinder ………………………………………………………….49
10.7 Oil leaks from parts of hydraulic system for breaker (Screw couplings, hoses etc.) ………49
10.8 Oil leaks from tool …………………………………………………………………………………………………49
10.9 Oil leaks from high-pressure accumulator ………………………………………………………………..49
10.10 Oil or grease leaks from JCB AUTOGREASE ……………………………………………………………50
10.11 Operating temperature too high ………………………………………………………………………………50
11 Disposal of Consumables ……………………………………………………………………………………….50
12 Hydraulic Oils, Filtering and Cooling ……………………………………………………………………51
13 Nitrogen Adaptor Reference Chart…………………………………………………………………………53
14 Tool Part Numbers………………………………………………………………………………………54
15 Breaker Part Number Matrix ……………………………………………………………..55
Total Pages: 444
This manual can be used by anyone from a first time owner/amateur to a professional technician. Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings. Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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Language: English