JCB Hammermaster/ Rockbreaker Repair Service Manual
JCB Hammermaster/ Rockbreaker Repair Service Manual
- This service manual PDF download for the JCB Hammermaster/ Rockbreaker has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/1300-12 Total Pages : 454
This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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9803-1300-12 9803-1300E_13-section 22 Cover Replacement Page Index Introduction
Section 1 - General Information and Safety 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 Hammermaster 1350 Hammermaster 1750 Hammermaster 2350/2950/3850 Hammermaster 550 Hammermaster 850 Service Tools Nord-Lock Washers Accumulator - Charging Safety Notices General Safety Operating Safety Maintenance Safety Safety Decals Lubricants - Health and Safety
Section 2 - Routine Maintenance Lubricants 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 550 Hammermaster 1050 Hammermaster 1350 Hammermaster 1750 Hammermaster 2350/2950/3850 Hammermaster 850 Service Schedules Greasing Side Plates (Hammermasters 160/160Q/160R/260/260L/260LQ/360/360Q/360-70/460-110) Checking Bolt Tightness Hanger Bracket (Hammermasters 550, 560 to 960 and 570 to 770) Checking Bolt/Nut Tightness Lower Tool Bushing and Tools Checking For Excessive Wear Checking For and Removing Burrs Lower Tool Bushing Hammermasters 160/160Q/160R/260/260L/260LQ/360/360Q/360-70 Removal Replacement Hammermaster 460-110 Removal Replacement Hammermasters 560, 660, 760, 860, 960 Removal Replacement Hammermasters 570, 670, 770 Removal Replacement Hammermaster 550 Removal Replacement Checking For and Removing Burrs Hammermaster 850, 1050, 1350, 1750, 2350, 2950 and 3850 Indexing the Lower Tool Bushing Removal Replacement Wear Limits and Lubricants Tool Wear Limits Hammermaster 850, 1050, 1350, 1750, 2350, 2950 and 3850 Hydraulic Pressure Testing Wear Limits for Thrust Rings Maximum Distance between Wear Plates Large Hammers Wear Limits for Buffers Large Hammers Accumulator Shield Plugs Large Hammers - 1050, 1350, 1750, 2350, 2950, 3850
Section 3 - Servicing - Hammermaster 260 Range Technical Data General Sideplates Removing (Hammermaster 260 - Early Models) Installing (Hammermaster 260 Early Models) Removing/Installing (Hammermaster 260L - Early Models) Removing/Installing (Hammermaster 260, 260L - Later Models) Removing/Installing (Hammermaster 260LQ) Swivel Couplings (if fitted) Removal and Dismantling Assembly and Replacement Low Pressure Accumulator Removing and Dismantling Assembling and Installing High Pressure Accumulator Removing and Dismantling Assembling and Installing Accumulator Charging Pressure Adjusting Valve Dismantling Assembling Adjustment Dismantling and Inspecting the Hammermaster Dsitributor Tie Rods Valve Body Piston and Cylinder Thrust Ring and Upper Tool Bushing Front Head Assembling the Hammermaster Upper Tool Bushing and Thrust Ring Cylinder, Piston and Seals Valve Body Tie Rods Distributor Accumulator, Pressure Adjsuting Valve and Sideplates Fault Finding
Section 4 - Servicing - Hammermaster 360 Range Technical Data General Sideplates Removing/Installing Swivel Couplings Removal and Dismantling Assembly and Replacement Accumulators Removal Replacement Dismantling Assembly Charging Pressure Adjusting Valve Dismantling Assembly Adjustment - old type spool Adjustment - New Type Spool Tie Rods Removal Inspection Replacement Valve Body Removal and Dismantling Assembly and Replacement Cylinder Removal Replacement Front Head Dismantling Assembly Fault Finding
Section 5 - Servicing - Hammermaster 460-110 Technical Data General Sideplates Removing Installing Swivel Couplings Removal and Dismantling Assembly and Replacement Accumulators Removal Replacement Low Pressure Accumulator - Dismantling Low Pressure Accumulator - Assembly High Pressure Accumulator - Dismantling High Pressure Accumulator - Assembly Untitled Valve Body Removal Replacement Dismantling Assembly Pressure Adjusting Valve Dismantling Assembly Adjustment Tie Rods Removal Inspection Replacement Cylinder Removal Replacement Front Head Dismantling Assembly Fault Finding
Section 6 - Servicing - Hammermaster 560 Technical Data General Wear Plates Checking ReplacingAdjusting Hammer Assembly Removing the Housing Installing the Housing Accumulator Removal Replacement Dismantling Assembly Charging Main Valve Dismantling Assembly Pressure Adjusting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspsection Replacement New Tie Rod Construction Cylinder Dismantling Assembly New Cylinder and Seal System Front Head Dismantling Assembly Front Head and Split Pins Fault Finding
Section 7 - Servicing - Hammermaster 660 Technical Data General Wear Plates Checking Replacing/Adjusting Hammer Assembly Removing from Housing Installing in Housing Accumulator Removal Replacement Dismantling Assembly Charging Main Valve Dismantling Assembly Pressure Adjusting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspection Replacement Cylinder Dismantling Assembly Front Head Dismantling Assembly Fault Finding
Section 8 - Servicing - Hammermaster 760 Technical Data General Wear Plates Checking Replacing/Adjusting Hammer Assembly Removing from Housing Installing in Housing Accumulator Removal Replacement Dismantling Assembly Charing Main Valve Dismantling Assembly Pressure Adjusting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspection Replacement New Tie Rod Construction Removal with Failure or Seizure Cylinder Dismantling Assembly Front Head Dismantling Assembly Fault Finding
Section 9 - Servicing - Hammermaster 860 Technical Data General Wear Plates Checking Replacing/Adjusting Hammer Assembly Up to Serial No. 860007 Removing from Housing Installing in Housing From Serial No. 860008 Removing from Housing Untitled Accumulator Removal Replacement Dismantling Assembly Charging Main Valve Dismantling Assembly Pressure Adjsuting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspection Replacement New Tie Rod Construction Removal with Failure or Seizure Cylinder Dismantling Assembly Front Head Dismantling Assembly Fault Finding
Section 10 - Servicing - Hammermaster 960 Technical Data General Wear Pads Checking Replacing/Adjusting Hammer Assembly Removing the Housing Installing the Housing Accumulator Removal Replacement Dismantling Assembly Charging Main Valve Dismantling Assembly Pressure Adjusting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspection Replacement New Tie Rod Construction Removal with Failure or Seizure Cylinder Dismantling Assembly Front Head Dismantling Assembly Fault Finding
Section 11 - Servicing - Hammermaster 160 Range Technical Data General Attachment Frame (Robot 150/165 Skid Steer Loader) Removing the Hammermaster 160Q Untitled Backhoe Attachment (Robot 150/165 Skid Steer Loader) Removing the Hammermaster 160R Installing the Hammermaster 160R Sideplates Hammermaster 160Q Removing Installing Hammermaster 160 Removing Installing Hammermaster 160R Removing Installing Accumulators Removal Replacement Dismantling Assembly Charging Pressure Adjusting Valve Dismantling Assembly Adjustment Tie Rods Removal Inspection Replacement Valve Body Removal and Dismantling Assembly and Replacement Cylinder Removal Replacement Front Head Dismantling Assembly Fault Finding
Section 12 - Servicing - Hammermaster 570, 670, 770 Technical Data Hammermaster 570 Hammermaster 670 Untitled General Wear Plates Checking Replacing/Adjusting Hammer Assembly Removing from Housing Installing in Housing Accumulator Removal Replacement Dismantling Assembly Charging Main Valve Dismantling Assembly Pressure Adjusting Valve Dismantling Adjustment Assembly Check Valve Dismantling Assembly Tie Rods Removal Inspection Replacement Removal with Failure or Seizure Cylinder Hammermaster 570 Dismantling and Assembly Hammermaster 670 Dismantling and Assembly Hammermaster 770 Dismantling and Assembly Front Head Dismantling Assembly Fault Finding
Section 13 - Servicing - Hammermaster 70 Technical Data General JCB Mini-Excavator Hammermaster Identification Sideplates Removal Installing Chisel Removal Installing Main Body Dismantling Inspection Assembly Front Body Dismantling Inspection Assembly Piston and Cylinder Bushes Dismantling Assembly Accumulators Dismantling Assembly Charging Charging Values Fault Finding Torque Settings Sideplates Checking Bolt Tightness Maintenance Materials Service Tools Service Schedules Greasing The Tool Bushings Hamamermaster Pivots
Section 15 - Servicing - Hammermaster 1050 Technical Data Hammermaster 1050 Hammermaster 1150 General Breaker Removing from the Housing Installing in the Housing Dismantling Assembly Main Valve Check Valve Pressure Adjusting Valve Accumulator Removal Replacement Dismantling Assembly Charging Tie Rods Removal Replacement Removal with Failure or Seizure Fault Finding
Section 16 - Servicing - Hammermaster 1350 Technical Data Hammermaster 1350, 1350Q Hammermaster 1450, 1450Q General Breaker Removing from the Housing Installing in the Housing Tie Rods Removal and Replacement Removal with Failure or Seizure Dismantling Assembly Main Valve Check Valve Presssure Adjusting Valve Accumulator Removal Replacement Dismantling Assembly Charging Fault Finding
Section 17 - Servicing - Hammermaster 1750 Technical Data General Breaker Removing from the Housing Installing in the Housing Tie Rods Removal Replacement Removal with Failure or Seizure Dismantling Assembly Main Valve Check Valve Pressure Adjusting Valve Accumulator Removal Replacement Dismantling Assembly Charging Fault Finding
Section 18 - Servicing - Hammermaster 2350/2950/3850 Technical Data HM 2350, 2950, 3850 Hammermaster 3950, 3950Q Location of Main Components General Breaker Removing from the Housing Installing in the Housing Dismantling Assembly Main Valve Check Valve Pressure Adjusting Valve Pressure Sequence Valve (not fitted to the HM3850) Accumulator Removal Replacement Dismantling Assembly Charging Tie Rods Removal Inspection Replacement Removal with Failure or Seizure Hammermaster 3850 - Modified Tie Rods and Tie Rod Nuts Fault Finding
Section 19 - Servicing - Hammermaster 850 Technical Data General Breaker Removal of Sideplates Installing the Sideplates Location of Main Components Dismantling and Assembly Pressure Adjusting Valve Accumulator Removal Replacement Dismantling Assembly Charging Charging Pressure Tie Rods Removal Replacement Removal with Failure or Seizure Fault Finding
Section 20 - Servicing - Hammermaster 100 Technical Data General JCB Mini-Excavator Hammermaster Identification Sideplates Removal/Replacement Tools Removing/Installing Lower Tool Bushing and Tools Lower Tool Bushing and Tools Lower Bushing - Replacement Checking For Excessive Wear Checking For and Removing Burrs Breaker Dismantling Assembly Accumulator Dismantling Assembly Charging Fault Finding Torque Settings Service Schedules Greasing The Tool Bushings Hammermaster Pivots Check Bolt Tightness
Section 21 - Servicing - Hammermaster 60 & 110 Technical Data Hammermaster 60 Hammermaster 110 General JCB Mini-Excavator Hammermaster Identification Sideplates - HM60 Removal Installing Sideplates - HM110 Removal Installing Tools Removing/Installing Choosing Main Body - HM60 Dismantling Inspection Assembly Main Body - HM110 Dismantling Inspection Assembly Front Body - HM60 & HM110 Dismantling Inspection Assembly Piston and Cylinder Bushes - HM60 & HM110 Dismantling Assembly Accumulators Dismantling Assembly Charging Charging Values Air Chamber Charging - HM110 only Fault Finding Torque Settings HM60 HM110 Maintenance Materials Service Tools Service Schedules Greasing The Tool Bushings Hammermaster Pivots