service repair manual

1. 6
Servicing - 560
17
Servicing - 1750
7
Servicing - 660
8
Servicing - 760
9
Servicing - 860
Servicing - 960
18
2350/
*Servicing - 2950/
3850/
3950
19
Servicing - 850
20
21
Servicing -
60/
110
Service
Manual
Hammermaster
Rockbreakers
PUBLISHED BY THE
JCB ATTACHMENTS
RIVERSIDE, RUGELEY
STAFFORDSHIRE, WS15 2WA
ENGLAND
Tel. ROCESTER (01889) 572700
PRINTED IN ENGLAND
Publication No. 9803/1300
1
General Information
& Safety 12
Servicing - 570/
670/770 Range
2
Routine
Maintenance 13
Servicing - 70
3
Servicing - 260
Range 14
Servicing - 550
4
Servicing - 360
Range 15
*Servicing - 1050/
1150
5
Servicing - 460-110
16
*Servicing - 1350/
1450
10
Servicing - 160
Range 11
Issue 10*
*Servicing - 100/
115

2. 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
12th Set Publication No. 9803/1300
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 Issue Page No Issue
Page No Issue
Page No Issue
Contents 10*
Introduction 3
Section 1
Contents 10*
1 - 1 4
1 - 2 5*
2 - 1 3
2 - 2 3
2 - 3 3
2 - 4 3
2 - 5 3
2 - 6 3
2 - 7 3
2 - 8 3
2 - 9 3
2 - 10 2
2 - 11 1
2 - 12 1
2 - 13 1
2 - 14 3*
2 - 15 3*
2 - 16 2
2 - 17 3*
2 - 18 2
2 - 19 2
3 - 1 9*
4 - 1 1
5 - 1 1
6 - 1 1
7 - 1 2
8 - 1 4
9 - 1 1
Section 2
Contents i 9*
Contents ii 5*
1 - 1 4
1 - 2 3
1 - 3 3
1 - 4 3
1 - 5 3
1 - 6 3
1 - 7 3
1 - 8 3
1 - 9 4
1 - 10 2
1 - 11 1
1 - 12 1
1 - 13 1
1 - 14 1
1 - 15 2*
1 - 16 2*
1 - 17 1
1 - 18 4*
1 - 19 2
2 - 1 3
3 - 1 6
3 - 2 5*
3 - 3 4
3 - 4 3
3 - 5 4
3 - 6 6
3 - 7 4
3 - 8 2
3 - 9 1
3 - 10 3
3 - 11 5
3 - 12 4
3 - 13 3
3 - 14 1
3 - 15 3
3 - 16 4*
3 - 17 2*
3 - 18 2*
3 - 19 2*
Section 3
Contents 4
1 - 1 4
2 - 1 3
3 - 1 4
3 - 2 1
4 - 1 3
5 - 1 3
5 - 2 3
5 - 3 3
5 - 4 4
5 - 5 2
6 - 1 3
7 - 1 3
7 - 2 2
8 - 1 2
8 - 2 2
8 - 3 3
8 - 4 2
9 - 1 2
9 - 2 2
Section 4
Contents 3
1 - 1 4
2 - 1 2
3 - 1 2
3 - 2 2
4 - 1 2
5 - 1 2
5 - 2 2
5 - 3 4
6 - 1 3
6 - 2 1
7 - 1 2
8 - 1 2
9 - 1 2
10 - 1 2
11 - 1 2
11 - 2 2
Section 5
Contents 1
1 - 1 1
2 - 1 1
3 - 1 2
4 - 1 1
5 - 1 1
5 - 2 2
5 - 3 1
6 - 1 2
7 - 1 2
8 - 1 1
9 - 1 1
10 - 1 2
11 - 1 1
11 - 2 1
Section 6
Contents 2
1 - 1 1
2 - 1 1
3 - 1 1
4 - 1 1
5 - 1 2
5 - 2 2
5 - 3 2
6 - 1 2
7 - 1 2
8 - 1 1
9 - 1 3
9 - 2 1
10 - 1 1
10 - 2 2
10 - 3 1
11 - 1 2
11 - 2 1
12 - 1 2
12 - 2 1
Section 7
Contents 2
1 - 1 1
2 - 1 1
3 - 1 2
4 - 1 1
5 - 1 2
5 - 2 2
5 - 3 1
6 - 1 2
7 - 1 2
8 - 1 1
9 - 1 3
9 - 2 1
10 - 1 1
10 - 2 1
11 - 1 2
12 - 1 2
12 - 2 1
Section 8
Contents 3
1 - 1 1
2 - 1 1
3 - 1 1
4 - 1 1
5 - 1 2
5 - 2 2
5 - 3 1
6 - 1 2
7 - 1 3
8 - 1 1
9 - 1 3
9 - 2 2
10 - 1 1
10 - 2 1
11 - 1 2
12 - 1 2
12 - 2 1
Section 9
Contents 3
1 - 1 1
2 - 1 1
3 - 1 2
4 - 1 2
5 - 1 1
5 - 2 2
5 - 3 1
6 - 1 2
7 - 1 2
8 - 1 1
9 - 1 3
9 - 2 2
10 - 1 1
10 - 2 1
11 - 1 2
12 - 1 2
12 - 2 1
Section 10
Contents 3
1 - 1 1
2 - 1 1
3 - 1 2
4 - 1 1
5 - 1 2
5 - 2 2
5 - 3 1
6 - 1 2
7 - 1 2
8 - 1 1
9 - 1 3
9 - 2 2
10 - 1 1
Date of Incorporation Signature
12
i

3. Page No Issue Page No Issue
Page No Issue
Page No Issue
10 - 2 2
11 - 1 2
12 - 1 2
12 - 2 1
Section 11
Contents 3
1 - 1 4
2 - 1 3
3 - 1 3
4 - 1 4
4 - 2 2
5 - 1 2
5 - 2 3
5 - 3 3
6 - 1 4
7 - 1 3
8 - 1 2
9 - 1 2
10 - 1 2
11 - 1 3
11 - 2 2
Section 12
Contents 2
1 - 1 1
1 - 2 1
1 - 3 1
2 - 1 1
3 - 1 2
4 - 1 1
5 - 1 1
5 - 2 1
5 - 3 1
6 - 1 2
7 - 1 1
7 - 2 1
8 - 1 1
9 - 1 2
9 - 2 1
10 - 1 1
10 - 2 2
10 - 3 1
10 - 4 2
10 - 5 1
10 - 6 2
11 - 1 2
12 - 1 1
12 - 2 1
Section 13
Contents 1
1 - 1 3
2 - 1 1
3 - 1 1
4 - 1 1
5 - 1 1
6 - 1 1
7 - 1 1
8 - 1 1
8 - 2 1
8 - 3 1
9 - 1 1
10 - 1 1
11 - 1 1
12 - 1 1
12 - 2 1
Section 14
Contents 1
1 - 1 2
4 - 3 3*
5 - 1 3*
5 - 2 3*
6 - 1 3*
6 - 2 3*
6 - 3 3*
6 - 4 3*
6 - 5 3*
6 - 6 3*
6 - 7 3*
6 - 8 1 *
7 - 1 3*
7 - 2 3*
Section 19
Contents 1
1 - 1 2
2 - 1 1
3 - 1 2
3 - 2 1
4 - 1 2
4 - 2 1
4 - 3 2
5 - 1 1
5 - 2 1
6 - 1 1
6 - 2 1
6 - 3 1
6 - 4 1
7 - 1 1
7 - 2 1
Section 20
Contents 2*
1 - 1 2*
2 - 1 2*
3 - 1 2*
4 - 1 2*
5 - 1 2*
5 - 2 2*
6 - 1 2*
6 - 2 2*
7 - 1 2*
7 - 2 2*
8 - 1 2*
9 - 1 2*
10 - 1 2*
10 - 2 2*
Section 21
Contents 1
1 - 1 1
1 - 2 1
2 - 1 1
3 - 1 1
3 - 2 1
4 - 1 1
5 - 1 1
5 - 2 1
6 - 1 1
7 - 1 1
8 - 1 1
8 - 2 1
8 - 3 1
8 - 4 1
9 - 1 1
10 - 1 1
10 - 2 1
11 - 1 1
12 - 1 1
12 - 2 1
2 - 1 1
3 - 1 1
3 - 2 1
3 - 3 1
4 - 1 2
4 - 2 2
5 - 1 1
5 - 2 1
Section 15
Contents 2*
1 - 1 3*
1 - 2 1*
2 - 1 2*
3 - 1 2*
4 - 1 2*
4 - 2 2*
4 - 3 3*
5 - 1 2*
5 - 2 2*
6 - 1 2*
6 - 2 2*
6 - 3 2*
6 - 4 2*
7 - 1 2*
7 - 2 2*
Section 16
Contents 2*
1 - 1 3*
1 - 2 1*
2 - 1 2*
3 - 1 2*
4 - 1 2*
4 - 2 2*
4 - 3 3*
5 - 1 2*
5 - 2 2*
6 - 1 2*
6 - 2 2*
6 - 3 3*
6 - 4 4*
7 - 1 2*
7 - 2 2*
Section 17
Contents 1
1 - 1 2
2 - 1 1
3 - 1 1
4 - 1 1
4 - 2 1
4 - 3 2
5 - 1 1
5 - 2 1
6 - 1 1
6 - 2 1
6 - 3 2
6 - 4 2
7 - 1 1
7 - 2 1
Section 18
Contents 3*
1 - 1 3*
1 - 2 3*
1 - 3 1*
2 - 1 3*
3 - 1 3*
4 - 1 3*
4 - 2 3*
ii

4. 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 = General Information & Safety - includes torque settings and service tools as well as warnings and
cautions pertinent to aspects of workshop procedures etc.
2 = Routine Maintenance - includes service schedules and recommended lubricants.
3 onwards = 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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