Jcb hammermaster 860 rockbreakers service repair manual

Service Manual

General Information & Safety

1

Servicing - 570/ 670/770 Range

12

Routine Maintenance

2

Servicing - 70

13

Servicing - 260 Range

3

Servicing - 550

14

Servicing - 360 Range

4

*Servicing - 1050/ 1150

Servicing - 460-110

5

*Servicing - 1350/ 1450

Servicing - 560

6

Servicing - 1750

Servicing - 660

7

2350/ *Servicing - 2950/ 3850/ 3950

Servicing - 760

8

Servicing - 850

19

Servicing - 860

9

*Servicing - 100/ 115

20

Servicing - 960

10

Servicing - 160 Range

11

Hammermaster Rockbreakers

PUBLISHED BY THE JCB ATTACHMENTS RIVERSIDE, RUGELEY STAFFORDSHIRE, WS15 2WA ENGLAND Tel. ROCESTER (01889) 572700 PRINTED IN ENGLAND Publication No. 9803/1300

15 16 17

18

Servicing -

60/ 110

21

Issue 10*

i

JCB SERVICE

CATALOGUE / MANUAL - REPLACEMENT PAGES * 60/110, 70, 100/115, 160-960, 570-770, 550, 850, 1050, 1150, 1350, 1450, 1750, 2350, 2950, 3850, 3950 Hammermaster Service Manual

Publication No. 9803/1300

12th Set

These pages should be inserted immediately in their correct positions and pages of a lower issue no. removed and destroyed.

The total contents of this publication can be checked using the index below. Retain index at front of book. Replacement pages issued in this set are indicated by an asterisk (*).

Page No Contents Introduction

Issue 10* 3

Section 1 Contents 1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2 - 10 2 - 11 2 - 12 2 - 13 2 - 14 2 - 15 2 - 16 2 - 17 2 - 18 2 - 19 3-1 4-1 5-1 6-1 7-1 8-1 9-1

10* 4 5* 3 3 3 3 3 3 3 3 3 2 1 1 1 3* 3* 2 3* 2 2 9* 1 1 1 2 4 1

Section 2 Contents i Contents ii 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1 - 10 1 - 11 1 - 12 1 - 13 1 - 14 1 - 15 1 - 16 1 - 17 1 - 18 1 - 19 2-1 3-1

9* 5* 4 3 3 3 3 3 3 3 4 2 1 1 1 1 2* 2* 1 4* 2 3 6

Date of Incorporation

Page No

Issue

3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3 - 10 3 - 11 3 - 12 3 - 13 3 - 14 3 - 15 3 - 16 3 - 17 3 - 18 3 - 19

5* 4 3 4 6 4 2 1 3 5 4 3 1 3 4* 2* 2* 2*

Section 3 Contents 1-1 2-1 3-1 3-2 4-1 5-1 5-2 5-3 5-4 5-5 6-1 7-1 7-2 8-1 8-2 8-3 8-4 9-1 9-2 Section 4 Contents 1-1 2-1 3-1 3-2 4-1 5-1 5-2 5-3 6-1 6-2 7-1 8-1 9-1 10 - 1 11 - 1

Page No

Issue

Page No

Issue

11 - 2

2

12 - 1 12 - 2

2 1

Section 5 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 10 - 1 11 - 1 11 - 2

1 1 1 2 1 1 2 1 2 2 1 1 2 1 1

4 4 3 4 1 3 3 3 3 4 2 3 3 2 2 2 3 2 2 2

Section 6 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 9-2 10 - 1 10 - 2 10 - 3 11 - 1 11 - 2 12 - 1 12 - 2

2 1 1 1 1 2 2 2 2 2 1 3 1 1 2 1 2 1 2 1

Section 8 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 9-2 10 - 1 10 - 2 11 - 1 12 - 1 12 - 2

3 1 1 1 1 2 2 1 2 3 1 3 2 1 1 2 2 1 3 1 1 2 2 1 2 1 2 2 1 3 2 1 1 2 2 1

3 4 2 2 2 2 2 2 4 3 1 2 2 2 2 2

Section 7 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 9-2 10 - 1 10 - 2 11 - 1

Section 9 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 9-2 10 - 1 10 - 2 11 - 1 12 - 1 12 - 2

2 1 1 2 1 2 2 1 2 2 1 3 1 1 1 2

Section 10 Contents 1-1 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 8-1 9-1 9-2 10 - 1

3 1 1 2 1 2 2 1 2 2 1 3 2 1

Signature

12

ii Page No

Issue

10 - 2 11 - 1 12 - 1 12 - 2

2 2 2 1

Section 11 Contents 1-1 2-1 3-1 4-1 4-2 5-1 5-2 5-3 6-1 7-1 8-1 9-1 10 - 1 11 - 1 11 - 2

3 4 3 3 4 2 2 3 3 4 3 2 2 2 3 2

Section 12 Contents 1-1 1-2 1-3 2-1 3-1 4-1 5-1 5-2 5-3 6-1 7-1 7-2 8-1 9-1 9-2 10 - 1 10 - 2 10 - 3 10 - 4 10 - 5 10 - 6 11 - 1 12 - 1 12 - 2

2 1 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1 2 1 2 1 2 2 1 1

Section 13 Contents 1-1 2-1 3-1 4-1 5-1 6-1 7-1 8-1 8-2 8-3 9-1 10 - 1 11 - 1 12 - 1 12 - 2

1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Section 14 Contents 1-1

1 2

Page No

Issue

2-1 3-1 3-2 3-3 4-1 4-2 5-1 5-2

1 1 1 1 2 2 1 1

Section 15 Contents 1-1 1-2 2-1 3-1 4-1 4-2 4-3 5-1 5-2 6-1 6-2 6-3 6-4 7-1 7-2

2* 3* 1* 2* 2* 2* 2* 3* 2* 2* 2* 2* 2* 2* 2* 2*

Section 16 Contents 1-1 1-2 2-1 3-1 4-1 4-2 4-3 5-1 5-2 6-1 6-2 6-3 6-4 7-1 7-2

2* 3* 1* 2* 2* 2* 2* 3* 2* 2* 2* 2* 3* 4* 2* 2*

Section 17 Contents 1-1 2-1 3-1 4-1 4-2 4-3 5-1 5-2 6-1 6-2 6-3 6-4 7-1 7-2

1 2 1 1 1 1 2 1 1 1 1 2 2 1 1

Section 18 Contents 1-1 1-2 1-3 2-1 3-1 4-1 4-2

3* 3* 3* 1* 3* 3* 3* 3*

Page No

Issue

4-3 5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 7-1 7-2

3* 3* 3* 3* 3* 3* 3* 3* 3* 3* 1* 3* 3*

Section 19 Contents 1-1 2-1 3-1 3-2 4-1 4-2 4-3 5-1 5-2 6-1 6-2 6-3 6-4 7-1 7-2

1 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1

Section 20 Contents 1-1 2-1 3-1 4-1 5-1 5-2 6-1 6-2 7-1 7-2 8-1 9-1 10 - 1 10 - 2

2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2* 2*

Section 21 Contents 1-1 1-2 2-1 3-1 3-2 4-1 5-1 5-2 6-1 7-1 8-1 8-2 8-3 8-4 9-1 10 - 1 10 - 2 11 - 1 12 - 1 12 - 2

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Page No

Issue

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training

by JCB Technical Training Department.

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 oil 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! The manual is compiled in numbered sections which contain information as follows:

*

1

=

2 3 onwards

= =

General Information & Safety - includes torque settings and service tools as well as warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance - includes service schedules and recommended lubricants.

Servicing - includes dismantling, overhaul etc. of specific components.

The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

9803/1300

Issue 3*

Section 1

General Information and Safety

Contents Hammermaster Identification Torque Settings Hammermaster 360 Range Hammermaster 460-110 Hammermaster 560 Hammermaster 660 Hammermaster 760 Hammermaster 860 Hammermaster 960 Hammermaster 160 Range Hammermaster 260 Range Hammermaster 570 Hammermaster 670 Hammermaster 770 Hammermaster 1050, 1150 Hammermaster 1350, 1450 Hammermaster 1750 Hammermaster 2350/2950/3850/3950 Hammermaster 550 Hammermaster 850

Section 1

Page No. 1-1

2-1 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2 - 10 2 - 11 2 - 12 2 - 13 2 - 14 2 - 15 2 - 16 2 - 17 2 - 18 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.

9803/1300

Issue 10*

Section 1

General Information and Safety

Section 1

1-2

1-2

Hammermaster Identification (continued)

B B 0385A

Hammermaster 760

0909A

* Hammermaster 570, 670, 770, 1050, 1150, 1350, 1450, 1750 and 2350/2950/3850/3950

B A 0386A 0903A

Hammermaster 550

Hammermaster 860

B A A1141 0387A

Hammermaster 960

9803/1300

Hammermaster 850

Issue 5*

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