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*
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