JCB JS330, JS450, JS460 Tracked Excavator Service Manual – 9803/6420-3

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JCB JS330, JS450, JS460 Tracked Excavator Service Manual – 9803/6420-3

This service manual PDF download for the JS330, JS450, JS460 JCB Tracked Excavator 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.

APPLICABLE MODELS :

JCB Tracked Excavator
JCB JS330 – from S/N: 712501 Onwards
JCB JS450 – from S/N: 714501 Onwards
JCB JS460 – from S/N: 714550 Onwards

TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Hydraulics
Transmission
Brakes
Track & Running Gear
Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/6420 Issue 3
Total Pages : 671

This JCB Hydraulic Excavator 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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Cover
Contents

General Information
Bolt and Nut Torque Specifications
Torque Settings
Service Tools
Section B – Body and Framework
Section C – Electrics
Section E – Hydaulics
Sealing and Retaining Compounds

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Fluids and Lubricants
Lubricants – Health and Safety
Service Schedules
Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher
Initial Precautions for New Machine Usage
Operating Hours Schedule
Greasing
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Excavator End
Battery
Hydraulics
Releasing Tank Pressure
Air Bleeding Procedures
Air Bleeding from Hydraulic Pump
Air Bleeding from Ram
Checking the Fluid Level
Topping up Fluid Level
Changing the Hydraulic Oil
Changing the Return Filter Element
Cleaning/Changing the Suction Strainer
Changing the Air Breather Element
Draining Tank Impurities
Changing the Pilot Oil Filter
Changing the Breaker In-line Filter
Changing the Drain Line Filter
Changing the Nephron Filter (JS450)
Changing the Plexus Filter (JS330/JS460)
Transmission
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil
Tracks and Running Gear
Cleaning the Tracks
Checking/Adjusting the Track Tension
Checking the Shoe Plate
Checking the Rollers and Idler Wheels for Oil Leaks
Engine
Changing the Air Filter Outer Element
Changing the Air Filter Inner Element
Checking the Oil Level
Changing the Oil and Filters
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Adjusting the Fan Belt
Fitting a New Fan Belt
Cleaning the Radiator and Oil Cooler
Draining Fuel Tank Impurities
Draining the Water Seperators
Changing the Fuel Filter Element
Bleeding the Fuel System
Component Location Diagram
Performance Evaluation
Checking the FOPS structure

Body and Framework
Cab – JS330/JS460
Direct Glazing
Undercarriage
JS330 Dimensions
JS450 Dimensions
JS460 Dimensions
Main Body
Weights – JS330/JS450
Maintenance Specifications – JS330
Boom and Slew Frame Installation
Boom Ram Installation
Dipper Ram Installation
Dipper Pivot Installation
Dipper and Dipper Ram Installation
Bucket Ram Installation
Dipper and Dipper Link Installation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Shim Adjustment Table
Air Conditioning
Operation
Control
Safety Procedures
Fault Finding
Checking Refrigerant Charge Level
Leak Testing
Tightening Leak Hoses
System Diagnosis

Electrics
The A.M.S System
Technical Data
Battery/Battery Testing
Schematic Diagram – JS330
Schematic Diagram – JS450
Schematic Diagram – Breaker/Crusher JS450
Schematic Diagram – JS330/JS460
Schematic Diagram – JS460 Tier 2
Controls and Instruments (CAPS II)
Right Console
Left Console
Monitor
Engine Control
Summary of Engine Functions
Stepping motor
Throttle Related Function
Stop Motor Function
Emergency Stop Button
Redundancy (Back-up) Throttle Control
Automatic Engine Speed Adjustment
Idling Control
Revolution Control for Each Mode
Control of Engine Speed for Breaker Operation
Engine Automatic Warm-up
Detection of Throttle Motor Assembly Defect
Engine Reverse Rotation Prevention
Pump Control (CAPS II)
Summary of Hydraulic System Functions
Schematic
Peformance Data
Flow Chart
Boom Lowering Speed Regulation
Cushioned Boom Starting
Pressure Increasing System
3-Speed Travel and Max. Flow (Q) Cut
Soft/Hard Switch
Power Supply Cut Delay
Swing Brake/Swing Lock
Lever Lock
Travel Warning
Overload Protection
Display Monitor
High Dump
Throttle Motor (CAPS II)
Throttle Motor and Throttle Link Replacment
Automatic Adjustment
Revolution Sensor
Installation
Self Test (CAPS II)
Fault Finding (CAPS II)
Fault Diagnosis
Emergency Engine Stop
Refuel
Coolant Refill
Air Cleaner Clogged
Low Engine Oil Pressure
Engine Oil Filter Blocked
Fluid Overheat, Water, Oil
Battery Charging
Electrical Systems, Message Fault
Engine Problem
Sensor Resistance Valve
Windscreen Wiper Motor

Hydraulics
Technical Data
JS330
JS450/460
Schematics
Schematic Hydraulic Circuit JS330
Schematic Hydraulic Circuit JS450
Pilot Control Line Schematic
Schematic Hydraulic Circuit JS460
Schematic Hydraulic Circuit JS460
Pressure Testing
Pressure Testing – JS330
Pressure Testing – JS450/460
Hydraulic Pump Regulator
JS330/JS450
Introduction, Specifications
Port Identification
Operation
JS330 – Tier2/JS460
Introduction, Specifications
Port Identification
Operation
Dismantling and Assembly
Fault Finding
Dismantling and Assembly – JS330/JS450
Regulator – JS460
Specifications
Operation
Fault Finding
Dismantling and Assembly
Control Valve
Precautions Before Use
Spool Location – JS330
Hydraulic Circuit Diagram – JS330
Spool Location – JS450/JS460
Hydraulic Circuit Diagram – JS450/JS460
Hydraulic Circuit Diagram JS450 Tier 2
Spool Location JS460 Tier 2
Operation – JS330
Removal and Replacement – Typical
Operation – JS450/JS460
Circuit Descriptions – JS330
Travel Functions
High Speed
Middle Speed
Low Speed
Linear Travel
Slew Functions
Zero Slewing
Slew Operation
Slew Brake
Slew Lock
Combined Slew and Dipper Closing
Excavator End Functions
Boom Up
Boom Down
Boom Down in L, F Mode
Boom Down Starting Delay
Dipper Opening
Dipper Closing
Bucket Opening
Bucket Closing
Combined Operations
Cushion Valve – Soft
Cushion Valve – Hard
High Dump
Pump Control
Maximum Flow Rate Cut
Negative Control
Hammer/Auxiliary/Merge
Circuit Descriptions – JS450/JS460
Travel Functions
High Speed
Middle Speed
Low Speed
Linear Travel
Slew Functions
Zero Slewing
Slew Operation
Slew Brake
Slew Lock
Combined Slew and Dipper Closing
Reverse Protection Valve
Excavator End Functions
Boom Up
Boom Down
Boom Down in L, F Mode
Boom Down Starting Delay
Dipper Opening
Dipper Closing
Bucket Opening
Bucket Closing
Combined Operations
High Dump
Pump Control
Maximum Flow Rate Cut
Negative Control
Hammer/Auxiliary/Merge
Crusher Circuit
Circuit Descriptions – JS460
Travel Circuit
Multi Function Travel and Boom Up
Hammer/Auxiliary/Merge
Circuit Descriptions JS460 Tier 2
Neutral Circuit
Travel Functions
Linear Speed
Middle Speed
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Closing
Priority Valves
Slew Circuit
Auxiliary/Merged Flow
Hammer
Remote Control Valve (Services)
Introduction, Specifcation
Remote Control Valve – Components
Operation
Dismantling and Assembly
Fault Finding
Remote Control Valve (Travel)
Introduction, Specification
Dismantling and Assembly
Shuttle Valve
Introduction
General Information
Slew Brake Valve – JS330
Introduction, Technical Data
Operation
8 Spool Solenoid
Hydraulic Rams
Specifications and Torque Settings
Precautions During Use
Bucket Ram Removal and Replacement
Dipper Ram Removal and Replacement
Boom Ram Removal and Replacement
Dismantling and Assembly
Re-Conditioning
Fault Finding
Maintenance Specifications
Testing the Hose Burst Check Valve – Arm Ram
Testing the Hose Burst Check Valve
Rotary Coupling
Operation – JS450
Operation – JS330/JS460
Removal and Replacement
Dismantling
Assembly
Slew Motor – JS330
Specifications
Hydraulic Motor Components
Motor Operating Principles
Slew Brake Operation
Dismantling
Inspection
Assembly
Fault Finding
Slew Motor JS460 Tier 2
Removal and Replacement
Dismantling
Inspection
Assembly
Slew Reduction Gear
Dismantling
Inspection
Assembly

Transmission
Traction Motor/Reduction Gear
Specification
Traction Motor
Brake Valve
Parking Brake
Travel Motor
Preparation for Use
Fault Finding
Removal and Replacement
Motor Bleeding
Traction Motor – JS330
Exploded View (Motor) – JS330
Component List (Motor) – JS330
Exploded View (Gearbox) – JS330
Component List (Gearbox) – JS330
Traction Motor – JS450
Exploded View (Motor) – JS450
Component List (Motor) – JS450
Traction Motor Exploded View – JS460
Traction Motor Component List – JS460
Traction Motor – JS330/JS450
Dismantling
Inspection
Assembly
Reduction Gear – JS330
Dismantling
Inspection
Assembly

Track and Running Gear
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Wear Limits
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Dismantling
Assembly
Drive Sprocket
Removal
Replacement
Wear Limits
Top Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits
Bottom Roller – JS460
Exploded Drawing

Engine
Technical Data

 

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JCB JS330, JS450, JS460 Tracked Excavator Service Manual – 9803/6420-3.pdf

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