service repair manual

1. 6Servicing - 560
17Servicing - 1750
7Servicing - 660
8Servicing - 760
9Servicing - 860
Servicing - 960
18
2350/
*Servicing - 2950/
3850/
3950
19Servicing - 850
20
21Servicing -
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
1General Information
& Safety 12Servicing - 570/
670/770 Range
2Routine
Maintenance 13Servicing - 70
3Servicing - 260
Range 14Servicing - 550
4Servicing - 360
Range 15*Servicing - 1050/
1150
5Servicing - 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 IssuePage No IssuePage 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 IssuePage No IssuePage 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*
*

23. Section 1 General Information and Safety
9803/1300
Section 1
Issue 10*
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.
*

25. Hammermaster Identification (continued)
0909A
1 - 2
Section 1 General Information and Safety
9803/1300
Section 1
1 - 2
Issue 5*
*
0385A
Hammermaster 760 Hammermaster 570, 670, 770, 1050, 1150, 1350, 1450,
1750 and 2350/2950/3850/3950
0903A
Hammermaster 550
A1141
Hammermaster 850
0386A
Hammermaster 860
0387A
Hammermaster 960
B
B
B
B
A
AA

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