JCB Hammermaster/ Rockbreaker Service Manual – 9803/1300-12

This workshop repair 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.

TABLE OF CONTENTS :

Section 1 – General Information and Safety
Section 2 – Routine Maintenance
Section 3 – Servicing – Hammermaster 260 Range
Section 4 – Servicing – Hammermaster 360 Range
Section 5 – Servicing – Hammermaster 460-110
Section 6 – Servicing – Hammermaster 560
Section 7 – Servicing – Hammermaster 660
Section 8 – Servicing – Hammermaster 760
Section 9 – Servicing – Hammermaster 860
Section 10 – Servicing – Hammermaster 960
Section 11 – Servicing – Hammermaster 160 Range
Section 12 – Servicing – Hammermaster 570, 670, 770
Section 13 – Servicing – Hammermaster 70
Section 14 – Servicing – Hammermaster 550
Section 15 – Servicing – Hammermaster 1050
Section 16 – Servicing – Hammermaster 1350
Section 17 – Servicing – Hammermaster 1750
Section 18 – Servicing – Hammermaster 2350/2950/3850
Section 19 – Servicing – Hammermaster 850
Section 20 – Servicing – Hammermaster 100
Section 21 – Servicing – Hammermaster 60 & 110
Section 22 – Servicing – Hammermaster 65

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 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 14 – Servicing – Hammermaster 550
Technical Data
General
Breaker
Dismantling
Assembly
Accumulator
Dismantling
Assembly
Pressure Adjusting Valve
Charging
Fault Finding

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

Section 22 – Servicing – Hammermaster 65

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