Jcb js330 tracked excavator service repair manual sn712501 onwards

Service
Manual
JS330
from machine no. 712501
JS450
JS460/500
JS460/500
machine no. 2410051 - 2410300
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
WORLD PARTS CENTREkjb.kjb.kjb
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6420
R
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Hydraulics E
FTransmission
GBrakes
JTrack & Running Gear
KEngine
Issue 4

9803/6420 Issue 1
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 earthmoving 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 al l
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the whole machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A = Attachments
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
Note: In this manual the term ‘swing’ may sometimes be used in place of ‘slew’ and the term ‘arm’ may sometimes be used in
place of ‘dipper’.

Contents Page No.
Bolt and Nut Torque Specifications 1 - 1
Torque Settings 1 - 2
Service Tools
Section B - Body & Framework 3 - 1
Section C - Electrics 4 - 1
Section E - Hydraulics 5 - 1
Sealing and Retaining Compounds 6 - 1
i
General Information
9803/6420
i
Issue 2*
Section 1 Section 1
*

JS330/JS450/460 and Variants
Tighten the bolts and nuts according to the table. Before and after daily work, check the bolts and nuts for looseness and for
those missing. Tighten if loose and renew if missing.
Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
Tightening Torque Table
Note: Use JCB Threadlocker and Sealer (High Strength) on those marked † and tighten to the torque listed in the above table.
The tightening torques for the bolts and nuts not listed above are as follows:
Bolt Wrench Tightening Torque
No Tightening Point Diameter mm Nm kgf m lbf ft
JS330/JS450-460 JS330/JS450-460 JS330/JS450-460 JS330/JS450-460 JS330/JS450-460
1† Travel Motor M24 36 900~1051 92~107 663~775
2† Drive Sprocket M20/M24 30/36 521~608/900~1051 53~62/92~107 384~448/663~775
3† Take-up Roller M16 24 267~312 27~32 197~230
4† Upper (Carrier) Roller (Standard) M16 24 267~312 27~32 197~230
(Heavy Duty) M18 27 371~432 38~44 273~318
5† Lower (Track) Roller M20/24 30/36 521~608/900~1051 53~62/92~107 384~448/603~775
6† Track Guard M20/24 30/36 521~608/900~1051 53~62/92~107 384~448/603~775
7 Shoe Bolt (Standard) M20 30 755~931 77~95 557~687
(Heavy Duty) M22 32 980~1180 100~120 723~871
8 Counter weight M27/M42 41/65 1335~1540/1470 136~158/150 985~1136/1084
9† Turntable Bearing (Lower Frame) M24 36 900~1050 92~107 664~775
10† Turntable Bearing (Slew Frame) M24 36 900~1050 92~107 664~775
11† Slew Equipment M24 36 900~1050 92~107 664~775
12† Engine (Engine Mount) M20 30 289~337 30~34 213~248
13† Engine Bracket M12&M14 19&22 108~127/176~196 11~13/18~20 79~93/130~144
14 Radiator M16 24 127~147 13~15 93~108
15† Hydraulic Pump M12 19 63~73 6.4~7.4 46~54
16† Oil Tank M16 24 196 20 144
17† Fuel Tank M16 24 245 25 180
18† Control Valve M16/M20 24/30 196/343 20/35 144/253
19† Rotating Joint M12&M16 19&24 65~95/245~290 7~10/25~30 48~70/180~214
20 Cab M16 24 128~142 13~15 94~105
21 Battery M10 17 20~29 2~3 14.7~21.4
1 - 1
Section 1 General Information
9803/6420
Section 1
1 - 1
Issue 3*
Bolt and Nut Torque Specifications
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt
Tightening
Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Torque
kgf m .69 1.7 3.3 5.9 9.9 13.9 20 28
lbf ft 5 12 24 43 72 101 145 203
Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head
Tightening
Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
bolt
Torque
kgf m .89 2.2 4.3 8.0 12 17.9 24.9 34.9
lbf ft 6.5 16 31 58 87 130 180 253
*

1 - 2
Section 1 General Information
9803/6420
Section 1
1 - 2
Issue 2*
Torque Settings
Torque Settings
Note 1: The figures quoted are for non-plated fasteners and are to be used only when there is no torque setting specified in the
relevant procedure in this service manual.
Note 2: The 4T grade settings DO NOT APPLY to fasteners used on the engine. If any 4T specification fasteners are found on
the engine, these must be tightened to the figure quoted in the relevant engine manual.
Bolt
Size Strength Grade of Bolt or Stud
4T 8.8 10.9 12.9
Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft
M3 0.39 0.04 0.28 - - - - - -
M4 0.78 0.08 0.57 - - - - - - - - -
M5 1.67 0.17 1.2 - - - - - - - - -
M6 2.84 0.29 2.1 8.04 0.82 5.9 11.3 1.15 8.3 - - -
M8 7.06 0.72 5.2 19.6 2.00 14.5 27.7 2.82 20.4 48 4.90 35.4
M10 14.0 1.43 10.3 39.1 3.99 28.8 55.0 5.61 40.6 94 9.2 66.4
M12 24.6 2.51 18.1 68.5 6.98 50.5 96.2 9.81 71 166 16.9 122
M16 61.9 6.31 45.7 173 17.6 127.6 242 24.7 178.5 400 40.8 295
M20 122 12.4 90 337 34.4 249 475 48.4 350 - - -
M22 167 17.0 123 464 47.3 342 652 66.5 481 - - -
M24 210 21.4 155 584 59.5 431 821 83.7 606 - - -
M27 311 31.7 229 864 88.1 637 1220 124 900 - - -
M30 420 42.8 310 1170 119 863 1650 168 1217 - - -
M33 576 58.7 425 1600 163 1180 2260 230 1667 - - -
M36 736 75.1 543 2050 209 1512 2880 294 2124 - - -
M39 961 98.0 709 2680 273 1977 3760 383 2773 - - -
M42 1190 121 878 3300 336 2434 4640 473 3422 - - -
M45 1490 152 1099 4140 422 3054 5820 593 4293 - - -
M48 1780 182 1312 4960 506 3659 6970 711 5141 - - -

3 - 1
General Notes
For the type of grease to use at each point, see Lubricants
and Capacities.
Do not mix different types of grease. Keep them separate.
Slew Ring Bearing
1 The three grease nipples are grouped together on the
front of the machine.
Slew Ring Teeth and Slew Pinion
Ensure slew ring is kept full of grease. Always grease
whenever the machine has been steam-cleaned.
For location of the slew ring gear refer to component
Location Diagrams .
1 Make the Machine Safe
Stop the engine and remove the starter key.
2 Grease the Slew Ring
a Remove the Inspection port cover A (on the
lower centre section).
b Remove the grease discharge port cover B (on
the lower inner side).
c Remove contaminated grease.
d Replace the discharge port cover.
e Apply grease to the slew ring via aperture C.
3 Slew the Machine
Start the engine and slew the machine a few degrees.
Stop the engine, remove the starter key and apply
grease again.
Repeat until the whole ring is greased. Check that
grease exudes around the entire circumference.
4 Refit the Cover
!! WARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will prevent
the engine being started.
8-3-1-3
Section 3 Routine Maintenance
9803/6420
Section 3
3 - 1
Issue 1
Greasing
JS03670
B
A
C

3 - 2
9803/6420
Section 3
3 - 2
Issue 2*
Greasing (continued)
Excavator End
16 Grease Points
!! WARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove the
starter key and disconnect the battery. This will prevent
the engine being started.
8-3-1-3
(No.)
Greasing Points Reference Number of greasing points
drawing
Boom 3.
Boom ram, eye end pin 1 2. Centralised greasing (total of 6 points)
Dipper ram, dump end pin 1.
Boom ram, dump end pin 2 2.
Bucket ram to Bucket linkage pin 2.
Bucket linkage to Bucket pin 3 1. (total of 5 points)
Dipper to Bucket Linkage pin 1.
Dipper to Bucket pin 1.
Bucket ram, dump end pin 1.
Dipper ram, eye end pin 4 1. (total of 3 points)
Boom to Dipper, connecting pin 1.
}
A357550
1
3
2
4
Note: The JS450/460 has the EMS (Easy Maintenance System) bearings, using a bush and plated pin system it is possible to
extend the excavator lubrication intervals to 1000 hours (this does not include bucket pins which should be greased at 50 hour
intervals).

3 - 3
9803/6420
Section 3
3 - 3
Issue 2*
Greasing (continued)
Excavator End
JS11110

4 - 1
First Aid - Electrolyte
EYES
FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL
HELP FAST.
IF SWALLOWED
DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES
OF WATER OR MILK. Then drink milk of magnesia, beaten
egg or vegetable oil.
SKIN
FLUSH WITH WATER. REMOVE AFFECTED CLOTHING.
!! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and naked flames.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage.
Keep metallic items (watches, rings, zippers etc) away
from the battery terminals. Such items could short the
terminals and burn you.
Set all switches in the cab to OFF before disconnecting
the battery. When disconnecting the battery, take off the
earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well-
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
5-3-4-3
!! CAUTION
Do not disconnect the alternator, the battery, or any part
of the charging circuit with the engine running.
8-3-4-1
Charge Rate Depending on the Battery specific Gravity
If the battery is charged and the charge rate is less than
75%, replace the battery.
Check the Electrolyte Level
1 Open the Battery Compartment A
Remove the two bolts B securing the metal plate above
the battery. Remove the plate C.
2 Check the Level
Remove covers and look at the level in each cell. The
electrolyte should be 6 mm. (0.25 inch) above the
plates. Top up if necessary with distilled water or
de-ionized water.
!! WARNING
Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
3 Check the Connections
Make sure that the terminals are tight and clean. Coat
them with petroleum jelly to prevent corrosion.
Refit the metal plate C above the battery. Refit the two
securing bolts B.
9803/6420
Section 3
4 - 1
Issue 2*
Battery
Temperature
20°C 0°C -10°C
Charge Rate
100% (satisfactory) 1.26 1.27 1.28
90% (satisfactory) 1.24 1.25 1.26
80% (charge) 1.22 1.23 1.24
75% (charge) 1.21 1.22 1.23
A357560
A357710
A
CC
BB

5 - 1
Releasing Tank Pressure
!! WARNING
DO NOT remove the hydraulic tank filler cap or cover
plate when the engine is running. The hydraulic system
is under pressure. You or others could be injured. First
stop the engine and then release the pressure.
8-3-4-4/1
!! WARNING
The temperature of the hydraulic oil will be high soon
after stopping the engine. Wait until it cools down (less
than 40°C) before beginning maintenance.
8-3-4-10
1 Prepare the Machine
Position the machine on level ground. Stop the engine.
Remove the starter key.
2 Locate the Hydraulic Oil Tank Filler Cap or Filler
Plate
Refer to Component Location Diagrams at the end of
this section.
3 Release Tank Pressure
Loosen air release plug A and allow tank pressure to
disperse. When no more air escapes loosen the plug a
bit further to confirm the tank is no longer pressurised.
Retighten the air release plug. Remove retaining screws
B and lift off filler plate C.
Air Bleeding Procedures
!! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1
9803/6420
Section 3
5 - 1
Issue 2*
Hydraulics
Air Bleeding Sequence
Air Bleeding
Air Bleeding Air Bleeding from slew Check
from pump from ram motor
Hydraulic oil or
pump replacement O O O O
Ram replacement O O
Slew motor
replacement O O
JS09771C
A
B

5 - 2
Air Bleeding Procedures (continued)
Air Bleeding from Hydraulic Pump
After Dismantling and Assembly
1 Open bleed port D and drain port R and bleed air.
2 When hydraulic oil flows from drain port R, close and
tighten plug.
3 Fill the pump with clean hydraulic fluid through bleed
port D until oil overflows. Close and tighten plug.
4 Start the engine and run at idling speed until the
complete system warms up.
5 Carefully loosen bleed plug D and release any trapped
air.
6 Repeat step 3 if necessary.
Note: See illustration for reversed port references on the
JS450 machine.
!! WARNING
8-3-4-10
After Changing the Hydraulic Fluid
Carry out steps 5 and 6 of After Dismantling and
Assembly.
9803/6420
Section 3
5 - 2
Issue 1
Hydraulics (continued)
JS09570
R
D
D
R
D
R
JS 330
JS 450

5 - 3
Air Bleeding Procedures (continued)
Air Bleeding from Ram
!! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1
!! WARNING
8-3-4-10
a Position the Machine on level ground.
b Idle the engine at low speed and retract each
ram 4 or 5 times without reaching the stroke end
(about 100mm (4 in.) before the end of the ram).
c Operate each ram 3 or 4 times to the stroke end to
completely bleed the air.
d Stop the engine and allow the bubbles to make their
way through the hydraulic tank.
Air Bleeding from the Slew Motor
!! WARNING
8-3-4-4/1
!! WARNING
8-3-4-10
a Position the machine on level ground.
b Idle the engine at low speed, loosen the air bleeding
plug A and check that oil comes out from the air
bleeding port.
DO NOT SLEW THE MACHINE.
c If no oil comes out, stop the engine, remove the air
bleeding plug A and fill the motor case with hydraulic
oil.
d Install the air bleeding plug. Tighten and then loosen
again.
e Idle the engine at low speed and continue to run
until oil comes out from the air bleeding port.
f Completely tighten the air bleeding plug.
g Idle the engine at low speed and slowly slew the
machine left to right evenly more than 2 turns.
h Stop the engine and allow the bubbles to make their
way through the hydraulic tank.
9803/6420
Section 3
5 - 3
Issue 1

5 - 4
For location of hydraulic oil tank see Component Location
Diagram.
!! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin get
medical help immediately.
INT-3-1-10/1
Checking the Fluid Level
Position the machine on level ground with the bucket
and dipper rams fully extended and the boom lowered to
rest the attachment on the ground, as at A.
2 Check the Level
Look at the fluid level in the sight tube B. The level
should be between the two marks on the tube. If the
fluid is cloudy, water or air has entered the system.
Water or air in the system could damage the hydraulic
pump.
Topping up Fluid Level
!! WARNING
8-3-4-4/1
Position the Machine on level ground as at A. Stop the
engine. Remove the starter key.
2 Locate the Hydraulic Oil Tank or Filler Plate
See Component location Diagrams.
See Releasing Tank Pressure.
4 Add Fluid.
a Remove plug C.
b Refill oil through the filler port using a suitable
tundish.
c Check the level through the level gauge on the side
of the tank.
d Refit plug C.
9803/6420
Section 3
5 - 4
Issue 2*
JS03640
B
A
JS09180
C

5 - 5
Changing the Hydraulic oil
!! WARNING
8-3-4-4/1
!! WARNING
Hydraulic Pressure
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil contains
harmful contaminants which can cause skin cancer. Do
not handle used engine oil more than necessary. Always
use barrier cream or wear gloves to prevent skin
contact. Wash skin contaminated with oil thoroughly in
warm soapy water. Do not use petrol, diesel fuel or
paraffin to clean your skin.
INT-3-2-3
Position the machine on level ground as at A. Stop the
engine. Remove the starter key.
2 Locate the Hydraulic oil tank or Filler Plate. See
Component Location Diagrams at the end of the
section.
4 Drain the Hydraulic Oil Tank
a Remove the filler port cover B and 'O'-ring C.
b Use a pump and discharge the hydraulic oil into an
empty waste container.
c Remove the drain plug D on the bottom of the Tank
and drain the remaining oil from the tank (have a
drain pan ready).
5 Replace the Suction Strainer E
See Changing the Suction Strainer.
6 Replace the Return Filter F
See Changing the Return Filter.
7 Seal the System
a Refit Drain plug D.
b Refill the Tank
Refill the Tank with Hydraulic oil (See Lubricants
and Capacities for the type of fluid) to the specified
level see Checking the Fluid Level.
c Install the 'O'-ring C and filler port cover B.
Note: If the 'O'-Ring C is damaged, replace it with a new
one.
8 Bleed the Hydraulic Components
See Air Bleeding Procedures
9803/6420
Section 3
5 - 5
Issue 1
JS10980
B
C
F
D
E
9 Check for Leaks
a Start the engine and run it for around 5 minutes
without load.
b Slowly operate the travel, slew and cylinders
several times.
10 Check the Fluid Level
See Checking the Fluid Level.
A

5 - 6
Changing the Return Filter Element
Remove the starter Key.
2 Locate the Return filter.
Refer to Components Location Diagrams at the end
of this section.
3 Release Tank Pressure.
4 Removing the Element
a Remove the retaining bolts B and take off cover
plate C complete with its ‘O’ ring seal.
b Remove spring D, by-pass valve E and element F.
5 Fit a New Element
Re-assemble in reverse order using a new filter element
F and a new cover plate ‘O’ ring.
6 Seal the System
Refit cover plate C and secure with bolts B.
9803/6420
Section 3
5 - 6
Issue 2*
JS11071
D
E
F
C
B

5 - 7
Cleaning/Changing the Suction Strainer
Position the machine on level ground.
Stop the engine. Remove the starter key.
2 Locate the Suction Strainer
4 Remove the suction Strainer
a Remove the retaining bolts A and washers D, lift off
cover plate B.
b Remove the suction strainer C and clean with a
suitable solvent or renew.
5 Fit the Suction Strainer
Fitting is a reversal of removal.
6 Check the Hydraulic fluid Level
7 Seal the System
Refit the cover plate B together with its 'O'-ring.
Note: Check the 'O'-ring, if it is worn or damaged replace it
with a new one and secure with bolts A and washers D.
9803/6420
Section 3
5 - 7
Issue 2*
JS11050
C
D AB

5 - 8
Changing the Air Breather Element
3 Remove Filler Cap A
4 Locate the Air Breather
See illustration.
5 Replace the Air Breather Element
Use an Allen key to remove socket head bolt which
secures the air breather element inside the cap.
Remove the element.
Fit and secure a new element.
6 Refit Filler Cap A
Line up the alignment marks and tighten fully. The
retaining pin will spring back to secure the filler cap.
9803/6420
Section 3
5 - 8
Issue 2*
JS11061
A

5 - 9
Draining Tank Impurities
Position the machine on level ground. stop the engine.
Remove the Starter Key.
3 Remove Filler Plate P
4 Drain the Tank Impurities
Open drain plug R and drain off accumulated water and
other deposits. This task is complete when clean
hydraulic fluid flows out.
5 Seal the System
Close drain plug R. Refit filler plate P and secure with
bolts G.
Changing the Pilot Oil Filter
(See Releasing Tank Pressure).
3 Locate the Pilot Oil Filter
4 Dismantle the Filter
a Using a wrench on the case, unscrew the filter case
A from the filter head B.
Take care not to spill the oil it contains.
b Remove and discard the element C and O-ring D.
5 Clean the Filter Base and Case
Discard any fluid in the filter case. Clean out the case
and the underside of the head.
6 Fit New Filter Components
a Coat the new O-ring D with hydraulic fluid and
locate in the filter head B.
b Coat the seal area of the new element C and install
it in the filter case A.
c Screw the filter case A to the head B and tighten
with the wrench.
9803/6420
Section 3
5 - 9
Issue2*
JS11072
P
G
A370340
R
A370370
JS03791
B
D
C
A

5 - 10
Changing the Breaker In-line Filter
Note: This filter should be changed at the intervals stated in
Service Schedules or when the visual indicator X has
popped up. DO NOT USE THE BREAKER WITH A
BLOCKED FILTER.
3 Locate the Filter
4 Remove the Oil Filter
Unscrew and remove filter A from head B.
5 Fit the New Filter
Coat the seal of the new filter with clean hydraulic fluid.
Screw the new filter into head B and tighten. Check and
top up the hydraulic fluid level.
Changing the Drain Line Filter
3 Locate the Filter
4 Remove the Oil Filter
Unscrew and remove filter A from head B.
5 Fit the New Filter
Coat the seal of the new filter with clean hydraulic fluid.
Screw the new filter into head B and tighten. Check and
top up the hydraulic fluid level.
9803/6420
Section 3
5 - 10
Issue 2*
JS06700
JS02830
A
X
A
B
B

5 - 11
9803/6420
Section 3
5 - 11
Issue 2*
JS09120
Changing the Nephron Filter (JS450)
!! WARNING
8-3-4-10
3 Remove the Nephron Filter A
a Close the two stop cocks B of the nephron filter
case C.
b Remove the retaining bolts D, washers E and lift the
cover F, together with the 'O'-ring G and spring H.
c Slowly lift the Nephron filter A and remove.
Note: Be careful not to drop any dirt from the nephron
filter A.
4 Replace the Nephron filter A
a Peel off the 4 foil seals of the new nephron filter (one
on the upper and lower side, and the other two on
the sides).
Note: If the foil is not removed, the filter will not function
properly.
b Slowly sink the new nephron filter A into its case.
c Install the spring H, 'O'-ring G and cover F, secure
with bolts D and washers E.
d Open the two stop cocks B on the nephron filter
case C.
5 Air Bleeding
a Start the engine and set at low idling, loosen the
plug I, tighten the plug when hydraulic oil flows out.
b Stop engine and Check the hydraulic oil level.
B
A
Close
Open
E
D G I H F
C

5 - 12
Changing the Plexus Filter (JS330/JS460)
!! WARNING
8-3-4-10
1. Prepare the Machine
2. Locate the Plexus Filter
Refer to the Identification of Machine Components.
3. Release Tank Pressure
4. Remove the Plexus Filter
a. Close the two filter case cocks B and C by turning
them to position X.
b. Remove bolts and washers E,
c Slacken the nuts G and insert the screws F to lift off
the cover D.
d Remove the cover D and remove the O-ring H.
e Lift up the Plexus filter A carefully and remove.
Take care not to drop any sediment.
5. Fit a New Element
a Slowly immerse the new Plexus filter A. Install the
O-ring H, cover D, nuts G and bolts F and bolts E.
b Torque tighten bolts E to 20Nm (15 lbf ft)
c Open the cocks B and C by turning them to position
Y.
6. Priming the Nephron Filter
a Start the engine and set at low idling, loosen plug J,
then tighten the plug when hydraulic oil flows out.
b. Stop the engine, check the hydraulic oil level and
top-up if low. (See Checking the Fluid Level).
9803/6420
Section 3
5 - 12
Issue 4*
E J
D
F
G
H
B
B
C
C
A
A
X
Y

Key
A filler/level plug
B level/drain plug
6 - 1
Checking the Track Gearbox Oil Level
Position the machine on level ground with the level and
filler plugs in the positions shown, with the filler plug
uppermost as at X.
2 Check the Level on One Side
Clean the area around filler plug A and level plug B and
remove both plugs. Oil should run from plug B. Top up
through plug A if necessary. (See Fluids and
Capacities for oil types).
3 Clean and Refit the Plug(s)
Make sure they are tight.
4 Check the Level on the Other Side
Repeat steps 1 to 3.
Changing the Track Gearbox Oil
Position the machine on level ground with the level/filler
plug A and drain plug B in the positions shown as at Y.
2 Drain the Oil on One Side
a Place a container below the drain plug to catch the
oil. The container must be large enough to hold the
maximum gearbox capacity (see Fluids and
Capacities).
!! CAUTION
Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the drain
plug.
2-3-4-2
b Remove filler/level plug A and drain plug B. Allow
the oil to drain out.
c Wipe the plugs clean. Make sure you remove all
metal particles.
d Wrap seal tape on the drain plug and refit.
3 Fill with New Oil
See Lubricants and Capacities for oil type and
volume.
a Pour new oil through filler/level plug A until oil runs
out of plug A.
b Clean and wrap seal tape around the plug. Tightly
refit filler/level plug A.
4 Change the Oil on the Other Side
Repeat steps 1 to 3.
5 Check for Leaks
Run the machine, operate the tracking controls and then
make sure there are no leaks.
9803/6420
Section 3
6 - 1
Issue 2*
Transmission
JS111
A
B A
B
X Y

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Checking the Slew Gearbox Oil Level
Position the machine on level ground. Stop the engine
and remove the starter key.
2 Locate the Slew Gearbox
See Component Location Diagrams at the end of this
section.
3 Check the Level
a Remove the dipstick A, wipe it clean and replace.
b Remove the dipstick again and check that the oil
level is within the range B.
c If necessary, top up through filler port C. (See
Fluids and Lubricants for oil type).
4 Replace the Dipstick.
Changing the Slew Gearbox Oil
Position the machine on level ground. Stop the engine
and remove the starter key.
2 Drain the Oil
a Remove the drain plug D. Allow the oil to drain out.
b Wipe the drain plug clean. Remove any metallic
particles.
c Refit the drain plug. Make sure it is tight.
3 Fill with New Oil
See Fluids and Lubricants for oil type and volume.
Fill with new oil through filler port C until it reaches the
full mark on the dipstick when settled. Replace the
dipstick.
4 Check for Leaks
Run the machine, operate the slew controls and make
sure there are no leaks.
9803/6420
Section 3
6 - 2
Issue 4*
Transmission (continued)6 - 2
JS330/JS450/JS460
AA
B
C
D

7- 1
Cleaning the Tracks
!! WARNING
If two people are doing this job make sure that the
person working the controls is a competent operator. If
the wrong control lever is moved, or if the controls are
moved violently, the other person could be killed or
injured.
If you will be working with another person, make sure
you both understand what the other will be doing. Learn
and use the recognised signalling procedures. Do not
rely on shouting - he will not hear you.
To clean the tracks you must turn them. When the tracks
are turning, keep clear of rotating parts.
Before starting this job, make sure that you have no
loose clothing (cuffs, ties, etc) which could get caught in
rotating parts.
Keep people not involved with the job well away!
8-3-3-1
Park the machine on level ground. Open the bucket and
slew the boom until it is at 90° to the track. Lower the
bucket to the ground.
2 Raise the Track
Operate the boom and dipper controls so that the track
on the side nearest the bucket is lifted up clear of the
ground.
3 Rotate the Track
!! WARNING
Rotating the tracks off the ground may cause stones and
other debris to be thrown with considerable force. If you
are on the outside, keep well clear. Keep other people
well clear.
8-3-3-2
When it is safe to do so and you are sure that everyone is
clear of the machine, operate the controls to rotate the track
which is off the ground. Rotate it first one way and then the
other to shake off the mud. If necessary, the person outside
may use water to get the mud off.
4 Inspect the Track
When you have finished, inspect the track rollers,
sprockets and idler wheels for damage and oil leaks.
5 Lower the Track
Operate the boom and dipper controls to lower the track
to the ground.
6 Repeat for the Opposite Track
Slew the boom round to the other side and repeat
steps 2 to 5 inclusive for the other track.
9803/6420
Section 3
7 - 1
Issue 2*
Tracks and Running Gear

7 - 2
Checking/Adjusting the Track Tension
Position the machine on level ground. Run it
backwards and forwards several times. Stop after
running it forwards.
Carry out steps 1 to 3 of Cleaning the Tracks. Block up
the undercarriage frame. Finish track rotation by running
the track forwards. Stop the engine and remove the
starter key.
!! WARNING
NEVER position yourself or any part of your body under a
raised machine which is not properly supported. If the
machine moves unexpectedly you could become
trapped and suffer serious injury or be killed.
INT-3-3-7
2 Check the Tension
Measure gap A in line with the third roller from the front
and between the lower surface of the track frame and
the upper surface of the shoe. The dimension should be
340-360 mm for hard ground conditions.
3 Adjust the Track Tension
Adjustment is made by either injecting or releasing
grease from the check valve B. Inject grease to reduce
the gap (increase the tension) or open to release grease
and increase the gap.
! WARNING
When opening the check valve always stand to one side
and loosen a little at a time until grease starts to come
out. If you over-loosen too much grease could spurt out
or the valve cover fly out and cause serious injury.
8-3-4-5
! WARNING
Under no circumstances must the check valve be
dismantled or any attempt made to remove the grease
nipple from the check valve
8-3-4-9
If a gap C exists between the idler wheel shaft and
the track frame, you may use pressure to apply the
grease. If there is no gap C after the application of
grease, then the necessary repairs must be carried out.
Note: Excessive tension can cause the track rail to wear the
drive rollers and sprocket, insufficient tension can cause
wear to the drive sprocket and track rail.
4 Lower the Track
Remove the blocks from beneath the undercarriage
and lower the track to the ground using the boom and
dipper controls.
5 Repeat for the Opposite Track
Slew the boom round to the other side and repeat steps
1 to 4 above.
9803/6420
Section 3
7 - 2
Issue 2*
Tracks and Running Gear (continued)
JS03770A
A343970
BB
CC
AA

Jcb js330 tracked excavator service repair manual sn712501 onwards

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