JCB JS330, JS450, JS460 and JS500 Tracked Excavator Service Repair Manual Instant Download (1)

1
1
General Information
2
Care Safety
3
Routine Maintenance
R
A
Attachments
Service Manual JS330 from machine no. 712501
B
Body Framework
C
Electrics
E
Hydraulics
JS450 from machine no. 714501 JS460/500 from
machine no. 714550 JS460/500 machine no. 2410051
- 2410300
F
Transmission
G
Brakes
J
PUBLISHED BY THE
Track Running Gear
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE WORLD PARTS CENTREkjb.kjb.kjb
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND Tel. ROCESTER [phone] PRINTED IN
ENGLAND
K
Engine
Publication No. 9803/6420 Issue 4
2
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.
9803/6420
Issue 1
3
General Information
Section 1
Section 1
i
i
Contents
Page No.
Bolt and Nut Torque Specifications
1 - 1
Torque Settings
1 - 2
Service Tools Section B - Body Framework
Section C - Electrics Section E - Hydraulics

3 - 1 4 - 1 5 - 1
Sealing and Retaining Compounds
6 - 1
Issue 2
4
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5
Section 1
General Information
Section 1
1 - 1
1 - 1
Bolt and Nut Torque Specifications
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
No Tightening Point Bolt Diameter JS330/JS450-460 Wrench mm JS330/JS450-460 Tightening Torque Tightening Torque Tightening Torque
No Tightening Point Bolt Diameter JS330/JS450-460 Wrench mm JS330/JS450-460 Nm kgf m lbf ft
No Tightening Point Bolt Diameter JS330/JS450-460 Wrench mm JS330/JS450-460 JS330/JS450-460 JS330/JS450-460 JS330/JS450-460
1 Travel Motor M24 36 9001051 92107 663775
2 Drive Sprocket M20/M24 30/36 521608/9001051 5362/92107 384448/663775
3 Take-up Roller M16 24 267312 2732 197230
4 Upper (Carrier) Roller (Standard) M16 24 267312 2732 197230
(Heavy Duty) M18 27 371432 3844 273318
5 Lower (Track) Roller M20/24 30/36 521608/9001051 5362/92107 384448/603775
6 Track Guard M20/24 30/36 521608/9001051 5362/92107 384448/603775
7 Shoe Bolt (Standard) M20 30 755931 7795 557687
(Heavy Duty) M22 32 9801180 100120 723871
8 Counter weight M27/M42 41/65 13351540/1470 136158/150 9851136/1084
9 Turntable Bearing (Lower Frame) M24 36 9001050 92107 664775
10 Turntable Bearing (Slew Frame) M24 36 9001050 92107 664775
11 Slew Equipment M24 36 9001050 92107 664775
12 Engine (Engine Mount) M20 30 289337 3034 213248
13 Engine Bracket M12M14 1922 108127/176196 1113/1820 7993/130144
14 Radiator M16 24 127147 1315 93108
15 Hydraulic Pump M12 19 6373 6.47.4 4654
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 M12M16 1924 6595/245290 710/2530 4870/180214
20 Cab M16 24 128142 1315 94105
21 Battery M10 17 2029 23 14.721.4

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 Diameter (size) Bolt Diameter (size) Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Hex. bolt Wrench mm 10 13 17 19 22 24 27 30
Hex. bolt Tightening Torque Nm 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.4
Hex. bolt Tightening Torque kgf m .69 1.7 3.3 5.9 9.9 13.9 20 28
Hex. bolt Tightening Torque lbf ft 5 12 24 43 72 101 145 203
Hex. socket head bolt Wrench mm 5 6 8 10 12 14 14 17
Hex. socket head bolt Tightening Torque Nm 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
Hex. socket head bolt Tightening Torque kgf m .89 2.2 4.3 8.0 12 17.9 24.9 34.9
Hex. socket head bolt Tightening Torque lbf ft 6.5 16 31 58 87 130 180 253
Issue 3
6
Section 1
General Information
Section 1
1 - 2
1 - 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 Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud Strength Grade of Bolt or Stud
Nm 4T kgf m lbf ft Nm 8.8 kgf m lbf ft Nm 10.9 kgf m lbf ft Nm 12.9 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 - - -
Issue 2
7
Section 3
Routine Maintenance
Section 3
3 - 1
3 - 1
Greasing
8 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
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
• 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 .
• Make the Machine Safe
• Stop the engine and remove the starter key.
• Grease the Slew Ring

1. Remove the Inspection port cover A (on the lower
   centre section).
2. Remove the grease discharge port cover B (on
   the lower inner side).
3. Remove contaminated grease.
4. Replace the discharge port cover.
5. Apply grease to the slew ring via aperture C.

C
A
B
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
JS03670
Issue 1
8
Section 3
Routine Maintenance
Section 3
3 - 2
3 - 2
Greasing (continued)
8 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
Excavator End
16 Grease Points
Greasing Points (No.) Reference drawing Number of greasing points
Boom Boom ram, eye end pin Dipper ram, dump end pin 1 3. 2. Centralised greasing (total of 6 points) 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.
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).
1
2
A357550
4
3
Issue 2
9
Section 3
Routine Maintenance
Section 3
3 - 3
3 - 3
Greasing (continued)
Excavator End
JS11110
Issue 2
10
Section 3
Routine Maintenance
Section 3
4 - 1
4 - 1
Battery
Check the Electrolyte Level 1 Open the Battery
Compartment A
First Aid - Electrolyte EYES FLUSH WITH WATER FOR
15 MINUTES. GET MEDICAL HELP FAST.
A A357560
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. 8 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.
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. 8 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.
5-3-4-3
8 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
B
??
Temperature Charge Rate 20C 0C -10C
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
A357710
If the battery is charged and the charge rate is
less than 75, replace the battery.
Issue 2
11
Section 3
Routine Maintenance
Section 3
5 - 1
5 - 1
Hydraulics
Releasing Tank Pressure 8 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 8 WARNING The temperature of
the hydraulic oil will be high soon after
stopping the engine. Wait until it cools down
(less than 40C) before beginning
maintenance. 8-3-4-10 1 Prepare the Machine
Position the machine on level ground. Stop the
engine. Remove the starter key.
A
B

• Locate the Hydraulic Oil Tank Filler Cap or
  Filler Plate
• Refer to Component Location Diagrams at the end
  of this section.
• Release Tank Pressure

??
JS09771
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 8 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
Air Bleeding Sequence
Check
Air Bleeding from pump
Air Bleeding from ram
Air Bleeding from slew motor
Hydraulic oil or pump replacement
O
O
O
O
Ram replacement
O
O
Slew motor replacement
O
O
Issue 2
12
Section 3
Routine Maintenance
Section 3
5 - 2
5 - 2
Hydraulics (continued)
Air Bleeding Procedures (continued) Air Bleeding
from Hydraulic Pump After Dismantling and Assembly
6 Repeat step 3 if necessary. Note See
illustration for reversed port references on the
JS450 machine. 8 WARNING The temperature of the
hydraulic oil will be high soon after stopping
the engine. Wait until it cools down (less than
40C) before beginning maintenance. 8-3-4-10

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.

1. Fill the pump with clean hydraulic fluid through
   bleed port D until oil overflows. Close and
   tighten plug.
2. Start the engine and run at idling speed until
   the complete system warms up.
3. Carefully loosen bleed plug D and release any
   trapped air.

After Changing the Hydraulic Fluid Carry out
steps 5 and 6 of After Dismantling and Assembly.
D
D
R
JS 330
D
R
R
JS 450
JS09570
Issue 1
13
Section 3
Routine Maintenance
Section 3
5 - 3
5 - 3
Hydraulics (continued)
Air Bleeding Procedures (continued) Air Bleeding
from Ram 8 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 8 WARNING The temperature of
the hydraulic oil will be high soon after
stopping the engine. Wait until it cools down
(less than 40C) before beginning
maintenance. 8-3-4-10 1 Prepare the Machine a
Position the Machine on level ground.
Air Bleeding from the Slew Motor 8 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
8 WARNING
The temperature of the hydraulic oil will be high
soon after stopping the engine. Wait until it
cools down (less than 40C) before beginning
maintenance. 8-3-4-10 1 Prepare the Machine 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.
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).
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.
c Operate each ram 3 or 4 times to the stroke
end to completely bleed the air.
d Install the air bleeding plug. Tighten and
then loosen again.
d Stop the engine and allow the bubbles to make
their way through the hydraulic tank.
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.
Issue 1
14
Section 3
Routine Maintenance
Section 3
5 - 4
5 - 4
Hydraulics (continued)
For location of hydraulic oil tank see Component
Location Diagram. 8 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
A B JS03640
Checking the Fluid Level
1 Prepare the Machine 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
8 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
C JS09180
1 Prepare the Machine 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.
3 Release Tank Pressure 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
Issue 2
15
Section 3
Routine Maintenance
Section 3
5 - 5
5 - 5
Hydraulics (continued)
Changing the Hydraulic oil
8 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.
A B C F E D JS10980
8-3-4-4/1
8 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
1 Prepare the Machine 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.
3 Release Tank Pressure See Releasing Tank
Pressure.
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).
9 Check for Leaks
a Start the engine and run it for around 5
minutes without load.
5 Replace the Suction Strainer E See Changing the
Suction Strainer.
b Slowly operate the travel, slew and cylinders
several times.
6 Replace the Return Filter F See Changing the
Return Filter.
10 Check the Fluid Level See Checking the Fluid
Level.

• Seal the System
• Refit Drain plug D.
• 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.
• Install the 'O'-ring C and filler port cover B.
• Note If the 'O'-Ring C is damaged, replace it
  with a new one.
• Bleed the Hydraulic Components
• See Air Bleeding Procedures

9803/6420
Issue 1
16
Section 3
Routine Maintenance
Section 3
5 - 6
5 - 6
Hydraulics (continued)
Changing the Return Filter Element
B C D E F JS11071
1 Prepare the Machine Position the machine on
level ground. Stop the engine. Remove the starter
Key.
2 Locate the Return filter. Refer to Components
Location Diagrams at the end of this section.
3 Release Tank Pressure. See Releasing 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.
Issue 2
17
Section 3
Routine Maintenance
Section 3
5 - 7
5 - 7
Hydraulics (continued)

• Cleaning/Changing the Suction Strainer
• Prepare the Machine
• Position the machine on level ground.
• Stop the engine. Remove the starter key.
• Locate the Suction Strainer
• Release Tank Pressure
• See Releasing Tank Pressure.
• Remove the suction Strainer
• a Remove the retaining bolts A and washers D,
  lift off

cover plate B.
D
A
B

• b Remove the suction strainer C and clean with a
  suitable solvent or renew.
• Fit the Suction Strainer
• Fitting is a reversal of removal.
• Check the Hydraulic fluid Level
• See Checking the Fluid Level.
• Seal the System
• Refit the cover plate B together with its
  'O'-ring.

C
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.
JS11050
Issue 2
18
Section 3
Routine Maintenance
Section 3
5 - 8
5 - 8
Hydraulics (continued)
Changing the Air Breather Element
A JS11061
1 Prepare the Machine Position the machine on
level ground. Stop the engine. Remove the starter
key.
2 Release Tank Pressure See Releasing Tank
Pressure.
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.
Issue 2
19
Section 3
Routine Maintenance
Section 3
5 - 9
5 - 9
Hydraulics (continued)
Draining Tank Impurities
G P JS11072 R A370340
1 Prepare the Machine Position the machine on
level ground. stop the engine. Remove the Starter
Key.
2 Release Tank Pressure See Releasing Tank
Pressure.
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
0 B D C A JS03
791
1 Prepare the Machine Position the machine on
level ground. Stop the engine. Remove the starter
key.
2 Release Tank Pressure (See Releasing Tank
Pressure).
3 Locate the Pilot Oil Filter

• 4 Dismantle the Filter
• 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.
• 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.
A37037
6 Fit New Filter Components

1. Coat the new O-ring D with hydraulic fluid and
   locate in the filter head B.
2. 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.
Issue 2
20
Section 3
Routine Maintenance
Section 3
5 - 10
5 - 10
Hydraulics (continued)
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.
X B A JS06700

• Prepare the Machine
• Position the machine on level ground. Stop the
  engine. Remove the starter key.
• Release Tank Pressure
• (See Releasing Tank Pressure).
• Locate the Filter
• Remove the Oil Filter
• Unscrew and remove filter A from head B.
• 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
B A JS02830

• Prepare the Machine
• Position the machine on level ground. Stop the
  engine. Remove the starter key.
• Release Tank Pressure
• (See Releasing Tank Pressure).
• Locate the Filter
• Remove the Oil Filter
• Unscrew and remove filter A from head B.
• 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.

Issue 2
21
Section 3
Routine Maintenance
Section 3
5 - 11
5 - 11
Hydraulics (continued)

• Changing the Nephron Filter (JS450)
• 8 WARNING
• The temperature of the hydraulic oil will be high
  soon after stopping the engine. Wait until it
  cools down (less than 40C) before beginning
  maintenance.
• 8-3-4-10
• Prepare the Machine
• Position the machine on level ground. Stop the
  engine. Remove the starter key.
• Release Tank Pressure
• See Releasing Tank Pressure.
• Remove the Nephron Filter A
• Close the two stop cocks B of the nephron filter
  case C.
• Remove the retaining bolts D, washers E and lift
  the cover F, together with the 'O'-ring G and
  spring H.
• Slowly lift the Nephron filter A and remove.
• Note Be careful not to drop any dirt from the
  nephron filter A.
• Replace the Nephron filter 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.
B
Close
F
D G I
H
E
c Install the spring H, 'O'-ring G and cover F,
secure with bolts D and washers E.
Open
d Open the two stop cocks B on the nephron
filter case C.
C A
5 Air Bleeding a Start the engine and set at low
idling, loosen the plug I, tighten the plug when
hydraulic oil flows out.
JS09120
b Stop engine and Check the hydraulic oil
level. See Checking the Fluid Level.
Issue 2
22
Section 3
Routine Maintenance
Section 3
5 - 12
5 - 12
Hydraulics (continued)
Changing the Plexus Filter (JS330/JS460) 8
WARNING The temperature of the hydraulic oil will
be high soon after stopping the engine. Wait
until it cools down (less than 40C) before
beginning maintenance. 8-3-4-10
J
E
D
A
F
G H A

• Prepare the Machine
• Position the machine on level ground. Stop the
  engine. Remove the starter key.
• Locate the Plexus Filter
• Refer to the Identification of Machine
  Components.
• Release Tank Pressure
• (See Releasing Tank Pressure).
• 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,
• Slacken the nuts G and insert the screws F to
  lift off the cover D.
• Remove the cover D and remove the O-ring H.
• Lift up the Plexus filter A carefully and remove.
• Take care not to drop any sediment.

X
B C
Y
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.
C

• Torque tighten bolts E to 20Nm (15 lbf ft)
• Open the cocks B and C by turning them to
  position
• Y.

B
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).
Issue 4
23
Section 3
Routine Maintenance
Section 3
6 - 1
6 - 1
Transmission

• Checking the Track Gearbox Oil Level
• Prepare the Machine
• Position the machine on level ground with the
  level and filler plugs in the positions shown,
  with the filler plug uppermost as at X.
• 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).
• Clean and Refit the Plug(s)
• Make sure they are tight.
• Check the Level on the Other Side
• Repeat steps 1 to 3.
• Changing the Track Gearbox Oil

• Prepare the Machine
• Position the machine on level ground with the
  level/filler plug A and drain plug B in the
  positions shown as at Y.
• 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).
• 8 CAUTION

X
Y
A
B
A
B
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
JS111

1. Remove filler/level plug A and drain plug B.
   Allow the oil to drain out.
2. Wipe the plugs clean. Make sure you remove all
   metal particles.
3. Wrap seal tape on the drain plug and refit.

Key

1. filler/level plug
2. level/drain plug

• Fill with New Oil
• See Lubricants and Capacities for oil type and
  volume.
• Pour new oil through filler/level plug A until
  oil runs out of plug A.
• Clean and wrap seal tape around the plug. Tightly
  refit filler/level plug A.
• Change the Oil on the Other Side
• Repeat steps 1 to 3.
• Check for Leaks
• Run the machine, operate the tracking controls
  and then make sure there are no leaks.

Issue 2
24
Section 3
Routine Maintenance
Section 3
6 - 2
6 - 2
Transmission (continued)
Checking the Slew Gearbox Oil Level 1 Prepare the
Machine
JS330/JS450/JS460
Position the machine on level ground. Stop the
engine and remove the starter key.
2 Locate the Slew Gearbox
A
A
See Component Location Diagrams at the end of
this section.
B
3 Check the Level a Remove the dipstick A, wipe
it clean and replace.
??

• Remove the dipstick again and check that the oil
  level is within the range B.
• If necessary, top up through filler port C. (See
• Fluids and Lubricants for oil type).

4 Replace the Dipstick. Changing the Slew Gearbox
Oil 1 Prepare the Machine
??

• Position the machine on level ground. Stop the
  engine and remove the starter key.
• Drain the Oil
• Remove the drain plug D. Allow the oil to drain
  out.
• Wipe the drain plug clean. Remove any metallic
  particles.
• Refit the drain plug. Make sure it is tight.
• 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.
• Check for Leaks
• Run the machine, operate the slew controls and
  make sure there are no leaks.

Issue 4
25
Section 3
Routine Maintenance
Section 3
7- 1
7 - 1
Tracks and Running Gear
Cleaning the Tracks 8 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
8 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.

• Inspect the Track
• When you have finished, inspect the track
  rollers, sprockets and idler wheels for damage
  and oil leaks.
• Lower the Track
• Operate the boom and dipper controls to lower the
  track to the ground.
• Repeat for the Opposite Track
• Slew the boom round to the other side and repeat
  steps 2 to 5 inclusive for the other track.

• Prepare the Machine
• 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.
• 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.
• Rotate the Track

Issue 2
26
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27
Section 3
Routine Maintenance
Section 3
7 - 2
7 - 2
Tracks and Running Gear (continued)
Checking/Adjusting the Track Tension
A JS03770
1 Prepare the Machine 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. 8
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
B ?? A A343970

• 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.
• 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.
• 8 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

• 8 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.
• Lower the Track
• Remove the blocks from beneath the undercarriage
  and lower the track to the ground using the boom
  and dipper controls.
• Repeat for the Opposite Track
• Slew the boom round to the other side and repeat
  steps
• 1 to 4 above.

9803/6420
Issue 2
28
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