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jcb JS330 Service Manual

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Service Manual

JS330

from machine no. 712501

JS450

from machine no. 714501

JS460

from machine no. 714550

Publication No. 9803/6420

Issue 3

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Summary of Contents for jcb JS330

Page 1 Service Manual JS330 from machine no. 712501 JS450 from machine no. 714501 JS460 from machine no. 714550 Publication No. 9803/6420 Issue 3...
Page 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.
Page 3 General Information Section 1 Section 1 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...
Page 4 20~29 14.7~21.4 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) Wrench Hex.
Page 5 General Information Section 1 Section 1 1 - 2 Torque Settings 1 - 2 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.
Page 6 Glass Lifter - minimum 2 off - essential for glass No plug supplied. Note: 110V models available upon installation, 2 required to handle large panes of glass. request - contact JCB Technical Service Ensure suction cups are protected from damage during storage.
Page 7 General Information Section 1 Section 1 3 - 2 3 - 2 Service Tools (cont’d) Body and Framework (Section B) (cont’d) S186310 S186340 Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass. (below) through original polyurethane seal.
Page 8 General Information Section 1 Section 1 3 - 3 3 - 3 Service Tools (cont’d) Body and Framework (Section B) (cont’d) S186470 S186550 Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
Page 9 Section 1 General Information Section 1 4 - 1 4 - 1 Service Tools SECTION C - ELECTRICS Electrical Test Equipment 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature Probe 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 892/00298...
Page 10 Section 1 General Information Section 1 5 - 1 5 - 1 Service Tools (continued) SECTION E - HYDRAULICS Hydraulic Pressure Test Gauges and Connections 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in 892/00347 Connector 892/00254 Hose...
Page 11 Section 1 General Information Section 1 5 - 2 5 - 2 Service Tools (continued) SECTION E - HYDRAULICS Hand Pump Equipment 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706...
Page 12 Section 1 General Information Section 1 5 - 3 5 - 3 Service Tools (continued) SECTION E - HYDRAULICS JS07050 Ram Piston Nut Removal/Fitting Spanner 993/99512 Spanner 55 mm A/F 993/99513 Spanner 60 mm A/F 993/99514 Spanner 65 mm A/F 993/99515 Spanner 70 mm A/F 993/99516...
Page 13 Section 1 General Information Section 1 5 - 4 5 - 4 Service Tools (continued) SECTION E - HYDRAULICS Socket Box Wrench For disassembly and assembly of slew motor gearbox. A408900 Nut Adapter For disassembly and assembly of slew motor gearbox.
Page 14 Section 1 General Information Section 1 5 - 5 5 - 5 Service Tools (continued) SECTION E - HYDRAULICS A408880 Seal Ring Tool for assembly and disassemble of slew motor gearbox seal Stopper for assembly of slew motor gearbox. A408890 9803/6420 Issue 1*...
Page 15 Section 1 General Information Section 1 5 - 6 5 - 6 Service Tools (continued) SECTION E - HYDRAULICS Bearing Rig for removal of slew motor bearing. A408870 9803/6420 Issue 1*...
Page 16 50 ml (High Strength) components. Gasketing for all sizes of flange where the strength of the joint is important. JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml JCB Threadlocker and Sealer...
Page 17 Care & Safety Section 2 Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/6420 Issue 1...
Page 18 Care & Safety Section 2 Section 2 1 - 1 1 - 1 In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. ! DANGER Denotes an extreme hazard exists.
Page 19 All construction and agricultural equipment can be Note: This section includes a certain amount of operating hazardous. When a JCB Excavator is correctly operated and safety information. But remember that whenever you drive properly maintained, it is a safe machine to work with. But...
Page 20 It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 9803/6420 Issue 1...
Page 21 Care & Safety Section 2 Section 2 4 - 1 4 - 1 Maintenance Safety ! WARNING ! WARNING Soft Ground Fires A machine can sink into soft ground. Never work under a If your machine is equipped with a fire extinguisher, make machine on soft ground.
Page 22 Care & Safety Section 2 Section 2 4 - 2 4 - 2 Maintenance Safety (cont’d) ! CAUTION ! WARNING Hydraulic Fluid Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and Fine jets of hydraulic fluid at high pressure can penetrate the render the machine inoperable.
Page 23 Changing the Breaker In-line Filter 5 - 10 Changing the Drain Line Filter 5 - 10 Changing the Nephron Filter(JS450) 5 - 11 Changing the Plexus Filter(JS330/JS460) 5 - 12 Transmission Checking Track Gearbox Oil Level 6 - 1 Changing the Track Gearbox Oil...
Page 24 Routine Maintenance Section 3 Section 3 Contents Page No. Engine Changing the Air Filter Outer Element 8 - 1 Changing the Air Filter Inner Element 8 - 2 Checking the Oil Level 8 - 3 Changing the Oil and Filter(s) 8 - 3 Checking the Coolant Level 8 - 4...
Page 25 SLEW GEARBOX JCB HD90 Gear Oil API-GL-5, MIL-L-2105 14.5 litres 18 litres (3.2 UK gal) (4 UK gal) TRACK ROLLERS JCB HD 90 Gear OIl API-GL-5, MIL-L-2105 IDLER WHEEL RECOIL SPRING JCB Special HP Grease Lithium based, No. 2 CYLINDER consistency...
Page 26 7-3-1-3/1 g. Wash dirty clothing before re-use. Hygiene h. Throw away oil-soaked shoes. JCB lubricants are not a health risk when used properly for Waste Disposal their intended purposes. All waste products should be disposed of in accordance with However, excessive or prolonged skin contact can remove all the relevant regulations.
Page 27 Section 3 Routine Maintenance Section 3 2 - 1 Service Schedules 2 - 1 Service Intervals for Hydraulic Oil and Filters when using a Breaker or Crusher When using a breaker or crusher, contamination and degradation of the hydraulic oil occurs much more quickly than in normal excavating use.
Page 28 Section 3 Routine Maintenance Section 3 2 - 2 Service Schedules 2 - 2 Initial Precautions for New Machine Usage ! CAUTION If the machine is operated at full load, before its initial run-in procedure is complete it may cause scuffing and seizing which can adversely effect the life of the machine.
Page 29 Section 3 Routine Maintenance Section 3 2 - 3 Service Schedules 2 - 3 Every 10 Operating Hours or Daily Every 100 Operating Hours or 2-Weekly Whichever occurs first Whichever occurs first 1. Clean 1. Do a 50 hour service plus: a.
Page 30 Section 3 Routine Maintenance Section 3 2 - 4 Service Schedules 2 - 4 Every 250 Operating Hours or Monthly Every 1000 Operating Hours or 6-Monthly Whichever occurs first Whichever occurs first 1. Do a 500 hour service plus: 1. Do a 100 hour service plus: 2.
Page 31 Section 3 Routine Maintenance Section 3 2 - 5 Service Schedules 2 - 5 Every 5000 Operating Hours or 2 Years 6 Months Whichever occurs first 1. Do a 1000 hour service plus: 2. Change Hydraulic oil (for machines with non biodegradable oil). Hydraulic tank air breather element.
Page 32 Routine Maintenance Section 3 Section 3 3 - 1 Greasing 3 - 1 ! WARNING General Notes You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the For the type of grease to use at each point, see Lubricants starter key and disconnect the battery.
Page 33 Routine Maintenance Section 3 Section 3 3 - 2 Greasing (continued) 3 - 2 ! WARNING Excavator End You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the 16 Grease Points starter key and disconnect the battery. This will prevent the engine being started.
Page 34 Routine Maintenance Section 3 Section 3 3 - 3 Greasing (continued) 3 - 3 Excavator End JS11110 9803/6420 Issue 2*...
Page 35 Routine Maintenance Section 3 Section 3 4 - 1 Battery 4 - 1 First Aid - Electrolyte Check the Electrolyte Level Open the Battery Compartment A EYES FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL HELP FAST. IF SWALLOWED DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES OF WATER OR MILK.
Page 36 Routine Maintenance Section 3 Section 3 5 - 1 Hydraulics 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.
Page 37 Routine Maintenance Section 3 Section 3 5 - 2 Hydraulics (continued) 5 - 2 Air Bleeding Procedures (continued) Repeat step 3 if necessary. Air Bleeding from Hydraulic Pump After Dismantling and Assembly Note: See illustration for reversed port references on the JS450 machine.
Page 38 Routine Maintenance Section 3 Section 3 5 - 3 Hydraulics (continued) 5 - 3 Air Bleeding Procedures (continued) Air Bleeding from Ram Air Bleeding from the Slew Motor ! WARNING ! WARNING DO NOT remove the hydraulic tank filler cap or cover Hydraulic Pressure plate when the engine is running.
Page 39 Routine Maintenance Section 3 Section 3 5 - 4 Hydraulics (continued) 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.
Page 40 Routine Maintenance Section 3 Section 3 5 - 5 Hydraulics (continued) 5 - 5 Changing the Hydraulic oil ! 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.
Page 41 Routine Maintenance Section 3 Section 3 5 - 6 Hydraulics (continued) 5 - 6 Changing the Return Filter Element Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter Key. Locate the Return filter. Refer to Components Location Diagrams at the end of this section.
Page 42 Routine Maintenance Section 3 Section 3 5 - 7 Hydraulics (continued) 5 - 7 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.
Page 43 Routine Maintenance Section 3 Section 3 5 - 8 Hydraulics (continued) 5 - 8 Changing the Air Breather Element Prepare the Machine Position the machine on level ground. Stop the engine. Remove the starter key. Release Tank Pressure See Releasing Tank Pressure. Remove Filler Cap A Locate the Air Breather See illustration.
Page 44 Routine Maintenance Section 3 Section 3 5 - 9 Hydraulics (continued) 5 - 9 Draining Tank Impurities Prepare the Machine Position the machine on level ground. stop the engine. Remove the Starter Key. Release Tank Pressure See Releasing Tank Pressure. Remove Filler Plate P Drain the Tank Impurities Open drain plug R and drain off accumulated water and...
Page 45 Routine Maintenance Section 3 Section 3 5 - 10 Hydraulics (continued) 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.
Page 46 Routine Maintenance Section 3 Section 3 5 - 11 Hydraulics (continued) 5 - 11 Changing the Nephron Filter (JS450) ! 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.
Page 47 Section 3 5 - 12 Hydraulics (continued) 5 - 12 Changing the Plexus Filter (JS330/JS460) ! 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.
Page 48 Routine Maintenance Section 3 Section 3 6 - 1 Transmission 6 - 1 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.
Page 49 Transmission (continued) 6 - 2 Checking the Slew Gearbox Oil Level Prepare the Machine JS330/JS450/JS460 Position the machine on level ground. Stop the engine and remove the starter key. Locate the Slew Gearbox See Component Location Diagrams at the end of this section.
Page 50 Routine Maintenance Section 3 Section 3 7- 1 Tracks and Running Gear 7 - 1 Cleaning the Tracks ! WARNING ! WARNING Rotating the tracks off the ground may cause stones and If two people are doing this job make sure that the other debris to be thrown with considerable force.
Page 51 Routine Maintenance Section 3 Section 3 7 - 2 Tracks and Running Gear (continued) 7 - 2 Checking/Adjusting the Track Tension 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.
Page 52 Routine Maintenance Section 3 Section 3 7 - 3 Tracks and Running Gear (continued) 7 - 3 Checking the Shoe Plate Prepare the Machine a Position the machine on level ground. Run it backwards and forwards several times. Stop after running it forwards.
Page 53 Routine Maintenance Section 3 Section 3 8 - 1 Engine 8 - 1 Stop the engine. Changing the Air Filter Outer Element Press clips A and lift off cover B. Remove outer ! CAUTION element C. Take care not to tap or knock the element. The outer element must be renewed immediately if the warning light on the instrument panel illuminates.
Page 54 Routine Maintenance Section 3 Section 3 8 - 2 Engine 8 - 2 Changing the Air Filter Inner Element Clean the inside of cover B and canister D. Note: Do not attempt to wash or clean the elements - they Carefully insert the new inner element G into the must only be renewed.
Page 55 Routine Maintenance Section 3 Section 3 8 - 3 Engine (continued) 8 - 3 Checking the Oil Level Prepare the Machine Park the machine on level ground. Lower the bucket to the ground. Stop the Engine Open the Engine Compartment Check the Oil Level Remove the dipstick A.
Page 56 Park the Machine on Level Ground To prevent the coolant freezing in cold conditions, antifreeze Stop the engine and let it cool down. Open the engine must be added. JCB Universal Antifreeze will give protection compartment. down to the temperatures shown in the table.
Page 57 Routine Maintenance Section 3 Section 3 8 - 5 Engine (continued) 8 - 5 Changing the Coolant Do Steps 1 and 2 of 'Checking the Coolant Level' Drain the System Open the radiator drain tap D. Remove the cylinder block drain plug E. Remove the expansion bottle cap B (see Checking the coolant Level).
Page 58 Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 Note: The JS330 has two belts and the JS450 and JS 460 has three belts. Check the Fan Belt Tension There must be 10 mm (0,4 in) slack at D on the belt.
Page 59 Routine Maintenance Section 3 Section 3 8 - 7 Engine (continued) 8 - 7 Cleaning the Radiator and Oil Cooler A clogged radiator and/or oil cooler can lead to engine overheating. Regularly check for a build-up of dirt and debris and, if necessary, use compressed air to clean out the grille.
Page 60 Routine Maintenance Section 3 Section 3 8 - 8 Engine (continued) 8 - 8 Draining Fuel Tank Impurities Stop the engine and remove the key. Loosen the drain tap A on the underside of the fuel tank. Drain the water and deposits until clean diesel oil flows out. Close the drain tap firmly.
Page 61 Routine Maintenance Section 3 Section 3 8 - 9 Engine (continued) 8 - 9 Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.
Page 62 Routine Maintenance Section 3 Section 3 9 - 1 Component Location Diagram 9 - 1 JS330/JS 450 Component Location Diagram A Fuel Tank B Hydraulic Tank C Engine D Pump E Exhaust F Counter Weight G Radiator Expansion Bottle H Radiator Oil Cooler...
Page 63 Routine Maintenance Section 3 Section 3 9 - 2 Component Location Diagram 9 - 2 JS 460 Component Location Diagram Fuel Tank Counter Weight Windscreen Washer Bottle Refuel Pump Hydraulic Tank Radiator Expansion Bottle Engine Breaker In-line Filter Radiator Oil Cooler Pump Air Cleaner Fuel Filters...
Page 64 Routine Maintenance Section 3 Section 3 10 - 1 Performance Evaluation 10 - 1 Introduction It is important before taking measurements that control conditions are maintained. a Position the machine on a level safe site. b Adhere strictly to the safety operation. c Confirm the setting when an adjustment is made.
Page 65 Routine Maintenance Section 3 Section 3 10 - 2 Performance Evaluation 10 - 2 Speed Measurements Bucket Ram speed. The conditions for checking are that the Dipper should be level. Measurement is of the time it takes the bucket to fully open and close from each end of the stroke Dipper Ram speed The conditions for checking are that the Dipper should...
Page 66 Routine Maintenance Section 3 Section 3 10 - 3 Performance Evaluation 10 - 3 Other Measurements Travel Linearity. MEASUREMENT METHOD The conditions for checking are that the vehicle should have an approach of 5 metres and a travel distance of 20 metres;...
Page 67 Routine Maintenance Section 3 Section 3 10 - 4 Performance Evaluation 10 - 4 Other Measurements (continued) Lateral Movement in Turntable Bearing. 1 First set the Dipper in a perpendicular position and 2 Install a dial gauge and set the needle to the Zero position the bucket 200 mm above the ground, stop Point.
Page 68 Routine Maintenance Section 3 Section 3 10 - 5 Performance Evaluation 10 - 5 Other Measurements (continued) Slew Brake 1 The slew brake performance is measured at the minimum slew position. Mark the turntable bearing and lower ring. Note: The person must stand well out of the machines slew radius on the front side, and also to confirm that no other personnel are in the vicinity.
Page 69 Routine Maintenance Section 3 Section 3 10 - 6 Performance Evaluation 10 - 6 Other Measurements (continued) Ram Piston Rod Seal Leakage As described below, check each ram in turn to determine the amount of leakage via the ram rod seal. 1 Extend the ram fully and wipe the piston rod and check that there are no scratches.
Page 70 Routine Maintenance Section 3 Section 3 12 - 1 12 - 1 FOPS Structure Checking the FOPS Structure All excavators are designed so that an operator’s Check that all the FOPS mounting bolts are in place and undamaged. Check the FOPS mounting bolts for correct protective structure can be fitted.
Page 71 2 - 2 JS 460 Dimensions 2 - 3 Main Body Weights - JS330/JS450 3 - 1 Maintenance Specifications - JS330 Boom and Slew Frame Installation 4 - 1 Boom Ram Installation 4 - 1 Dipper Ram Installation 4 - 2...
Page 72 Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools, Section 1). The work must only be carried out in a dry, frost free environment.
Page 73 Section B Section B 1 - 2 1 - 2 Direct Glazing - JS330/460 only (cont'd) Removing the Broken Glass and Old Sealant (cont'd) Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
Page 74 Section B 1 - 3 1 - 3 Direct Glazing - JS330/460 only (cont'd) Removing the Broken Glass and Old Sealant (cont'd) b Cut-out Knife F. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to Service Tools, Section (i) Insert the knife blade into the sealant.
Page 75 Section B Section B 1 - 4 1 - 4 Direct Glazing - JS330/460 only (cont'd) Preparing the New Glass Make sure that the new glass correctly fits the frame aperture K. a Put two spacer blocks L onto the bottom part of the frame aperture.
Page 76 Section B Section B 1 - 5 1 - 5 Direct Glazing - JS330/460 only (cont'd) Preparing the New Glass (cont'd) Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note 2 below) into a suitable applicator gun:...
Page 77 Body & Framework Section B Section B 1 - 6 1 - 6 Direct Glazing - JS330/460 only (cont'd) Installing the New Glass (cont'd) Make the inside seal smooth: a Wearing surgical gloves, dip your finger in a soapy water solution.
Page 78 Body & Framework Section B Section B 2 - 1 Undercarriage 2 - 1 JS330 - Dimensions 9803/6420 Issue 1...
Page 79 Body & Framework Section B Section B 2 - 2 Undercarriage 2 - 2 JS450 - Dimensions PCD 847.3 512.5 512.5 2197.5 2197.5 4395 5470 9803/6420 Issue 1...
Page 80 Body & Framework Section B Section B 2 - 3 Undercarriage 2 - 3 JS460 - Dimensions 1400 1832 4360 4340 800,23 9803/6420 Issue 1...
Page 81 Body & Framework Section B Section B 3 - 1 Main Body 3 - 1 Weights 9803/6420 Issue 1...
Page 82 Body & Framework Section B Section B 3 - 2 Main Body 3 - 2 Weights JS330 fitted with 6.45m boom, 600 grouse shoes, 1.2 m bucket JS450 fitted with 7.1m boom, 600 grouse shoes, 1.2 m bucket Symbol Position Weight (kg)
Page 83 Section B Section B 3 - 3 Main Body 3 - 3 Weights JS330 fitted with 6.45m boom, 600 grouse shoes, 1.2 m bucket JS450 fitted with 7.1m boom, 600 grouse shoes, 1.2 m bucket Part Name Dry Weight (kg)
Page 84 Body & Framework Section B Section B 4 - 1 Maintenance Specification 4 - 1 Attachments Boom and Slew Frame Installation JS330 9803/6420 Issue 2*...
Page 85 Body & Framework Section B Section B 4 - 2 Maintenance Specification 4 - 2 Attachments (continued) Dipper Ram Installation JS330 9803/6420 Issue 2*...
Page 86 Body & Framework Section B Section B 4 - 3 Maintenance Specification 4 - 3 Attachments (continued) Dipper Pivot Installation JS330 9803/6420 Issue 2*...
Page 87 Body & Framework Section B Section B 4 - 4 Maintenance Specification 4 - 4 Attachments (continued) Bucket Ram Installation JS330 9803/6420 Issue 2*...
Page 88 Body & Framework Section B Section B 4 - 5 Maintenance Specification 4 - 5 Attachments (continued) Bucket and Bucket Link Installation JS330 9803/6420 Issue 2*...
Page 89 Body & Framework Section B Section B 4 - 6 Maintenance Specification 4 - 6 Attachments (continued) Bucket and Dipper Installation JS330 9803/6420 Issue 2*...
Page 90 Body & Framework Section B Section B 4 - 7 Maintenance Specification 4 - 7 Attachments (continued) Shim Adjustment Table 9803/6420 Issue 1...
Page 91 Body & Framework Section B Section B 4 - 8 Maintenance Specification 4 - 8 Attachments (continued) Shim Adjustment Table 9803/6420 Issue 1...
Page 92 Body & Framework Section B Section B 12 - 1 Air Conditioning 12 - 1 Direction of flow through air conditioning system A306820 Compressor Condenser Receiver/Drier Expansion Valve Evaporator Coil Air Filter Air Filter 9803/6420 Issue 1...
Page 93 Body & Framework Section B Section B 12 - 2 Air Conditioning 12 - 2 Operation The compressor 1 draws in low pressure refrigerant gas from To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air the suction line (evaporator to compressor) and increases conditioning system recirculates, clean, dehumidified air into refrigerant pressure through compression.
Page 94 Body & Framework Section B Section B 12 - 3 Air Conditioning 12 - 3 Operation (cont'd) Note: In dusty conditions, it is recommended that air be recirculated within the cab, otherwise the filter may become clogged. Two air vents M are located in the cab rear panel, and two air vents N and P are located on the right hand console.
Page 95 Body & Framework Section B Section B 12 - 4 Air Conditioning 12 - 4 Operation (cont'd) Safety Procedures The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve 4, which meters The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly the amount of refrigerant entering the evaporator.
Page 96 Body & Framework Section B Section B 12 - 5 Air Conditioning 12 - 5 Fault Finding Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. Fault indications are given in the table below. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment.
Page 97 Body & Framework Section B Section B 12 - 6 Air Conditioning 12 - 6 9803/6420 Issue 1...
Page 98 Body & Framework Section B Section B 12 - 7 Air Conditioning 12 - 7 Fault Finding (cont'd) No Air Conditioning CHECK ACTION Are the controls set correctly, i.e. air conditioning YES: Check 2 selected, thermostat switch set to coldest position Reset controls and retest.
Page 99 Body & Framework Section B Section B 12 - 8 Air Conditioning 12 - 8 Checking Refrigerant Charge Level Leak Testing ! WARNING The pressure in the system, i.e. the refrigerant charge level Leak testing in Air Conditioning systems should be can be determined by checking the state of refrigerant at the carried out only in a well ventilated area.
Page 100 Body & Framework Section B Section B 12 - 9 Air Conditioning 12 - 9 System Diagnosis Normally Functioning A/C System Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed Gauge Readings: and the readings are stable and that the system has a full Low Side Gauge - Normal.
Page 101 Body & Framework Section B Section B 12 - 10 Air Conditioning 12 - 10 System Diagnosis (cont'd) Low R-134a Charge LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low. Other symptoms: Sight Glass - Bubbles continuously visible.
Page 102 Body & Framework Section B Section B 12 - 11 Air Conditioning 12 - 11 System Diagnosis (cont'd) No Refrigerant Circulation LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: Zero to negative Low Side Gauge - Zero to negative. High Side Gauge - Low. Other symptoms: Receiver-Drier - Frost or moisture on tubes before and after receiver-drier.
Page 103 Body & Framework Section B Section B 12 - 12 Air Conditioning 12 - 12 System Diagnosis (cont'd) Air in System LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: High High Low Side Gauge - High. High Side Gauge - High. Other symptoms: Sight Glass - Bubbles visible during system operation.
Page 104 Body & Framework Section B Section B 12 - 13 Air Conditioning 12 - 13 System Diagnosis (cont'd) Compressor Malfunction LOW SIDE (RED) HIGH SIDE (BLUE) Gauge Readings: High Low Side Gauge - High. High Side Gauge - Low. Diagnosis: Internal compressor leak...
Page 105 2 - 5 Schematic Diagram - Breaker/Crusher JS450 2 - 6A Schematic Diagram - JS330/JS460 2 - 7 (JS330/460 Schematic from 9803/6450 Page C 1-4) Schematic Diagram - JS460 Tier 2 2 - 8 Controls and Instruments (CAPS II) Right Console...
Page 106 Section C Electrics Section C Contents Page No. Fault Finding (CAPS II) Fault Diagnosis 9 - 1 Emergency Engine Stop 9 - 4 Refuel 9 - 5 Coolant Refill 9 - 6 Air Cleaner Clogged 9 - 7 Low Engine Oil Pressure 9 - 8 Engine Oil Filter 9 - 9...
Page 107 1 - 1 Technical Data 1 - 1 The A.M.S. system The JCB A.M.S. system (Advanced Management System) is a whole machine electronic control system which replaces the CAPS II system. The system controls engine speed, pump power, transmission, excavator functions, lights, wiper, auxiliary circuits, warning lamps, etc.
Page 108 Electrics Section C Section C 2 - 1 *Technical Data CAPS II 2 - 1 Circuit Protection; Fuse rating and circuit names BACK UP COMPUTER P. KEY SW. COMPUTER C. AIRCON., HEATER SHUT DOWN LAMP LEVER LOCK LAMP (SPARE) LUBRICATOR LAMP (SPARE) WARNING BEACON LAMP (SPARE)
Page 109 Spare Not used (Wheeled machine only) Not used (Wheeled machine only) Not used (Wheeled machine only) Not used (Wheeled machine only) Un-used Un-used JS330 and JS460 Pre-heat relay Main fuses Pre-heat resistor Battery isolator relay Safety relay 9803/6420 Issue 1*...
Page 110 Electrics Section C Section C 2 - 2 2 - 2 Batteries Testing - Specific Gravity Readings should be as tabulated and should not vary The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken between cells by more than 0.04.
Page 111 Electrics Section C Section C 2 - 3 Schematic Diagram 2 - 3 Main Components - JS330 (CAPS II) Cigar Lighter Throttle Motor Speaker Fuel Sensor Antenna Cord Thermo Switch (Hyd.) Radio Set Level Switch (Reserve Tank) Controller (Computer) Air Filter Sensor...
Page 113 Electrics Section C Section C 2 - 5 Schematic Diagram 2 - 5 Main Components - JS450 Cigar Lighter Pressure Switch (Sump Tank) Controller (Computer) Throttle Motor Fuse Box Warning Buzzer Starter Switch Switch Panel (LH) High Dump Switch Limit Switch (Gate) Limit Switch (Console) Switch (Horn) Switch (Throttle Volume)
Page 115 Electrics Section C Section C 2 - 6A Circuit Daigram - Breaker/Crusher -JS450 2 - 6A 9803/6420 Issue 2*...
Page 116 Electrics Section C Section C 2 - 7 Schematic Diagram 2 - 7 Main Components - JS330/JS460 -AMS Refer to Service manual Supplement 9803/6450 Electronic Control Unit Switch Cap (Hazzards) Electronic Monitor System Column Switch Facia Switch Panel Headlamp (RH Dip)
Page 117 Section C Section C Electrics 1 - 4 Schematic Diagram 1 - 4 9803/6450 Issue 2*...
Page 118 Section C Electrics Section C 2 - 8 Schematic Diagram 2 - 8 Main Components JS 460 Tier 2 The item numbers in the following list are identified on the wiring schematic. Description Electronic Control Unit (ECU) Electonic Montior System (EMS) Facia Switch Panel Fuse Box Assembly Throttle Dial...
Page 120 Electrics Section C Section C 3 - 1 Controls and Instruments (CAPS II) 3 - 1 Right Console For correct operation and description see 'Operator’s Manual' RIGHT CONSOLE Idle Switch Throttle Volume Control JS03020 Work Lamp Switch Mode Selection Wiper Switch One Touch/Auto change switch Washer Switch...
Page 121 Electrics Section C Section C 3 - 2 Controls and Instruments (CAPS II) 3 - 2 Right Console (continued) Horn Volume Soft/Hard Starter Switch Buzzer Stop Switch Right Console (side panel) Time Adjust Back-up 9803/6420 Issue 2*...
Page 122 Electrics Section C Section C 3 - 3 Controls and Instruments (CAPS II) 3 - 3 Left Console For correct operation and description see 'Operator’s Manual' LEFT CONSOLE Lever-lock Switch Horn Switch CONTROLS OFF JS03000 Cigarette Lighter Hour Meter Emergency Stop Switch STOP Heater and Air Conditioning Fan Speed...
Page 123 Electrics Section C Section C 3 - 4 Controls and Instruments (CAPS II) 3 - 4 Monitor For correct operation and description see 'Operator’s Manual' WORK MODE Message MODE CLOCK WATER TEMP HYD. OIL TEMP FUEL Water Temp Travel Mode Indicators Green White...
Page 124 Electrics Section C Section C 4 - 1 Engine Control (CAPS II) 4 - 1 Summary of Engine Functions For more information about the electrically controlled functions listed below, refer to the detailed descriptions on the following pages. Each detailed description is identified by the same number as that used below. Stop motor function Emergency stop button ON Redundancy (Back-up)
Page 125 Electrics Section C Section C 4 - 2 Engine Control (CAPS II) 4 - 2 General Basic Operation The engine throttle control is done with the electric throttle motor. A stepping motor is now used as part of the throttle motor. Stepping Motor This rotates in direct synchronization with the amount of pulses received from the pulse oscillator.
Page 126 Electrics Section C Section C 4 - 3 Engine Control (CAPS II) 4 - 3 General (continued) Stepping Motor (continued) Driver Circuit (driver) The driver circuit of a stepping motor consists of a logical section which forms and distributes a pulsed signal from an oscillator and an amplifying section which amplifies and supplies the signal to the motor.
Page 127 Electrics Section C Section C 4 - 4 Engine Control (CAPS II) 4 - 4 General (continued) Throttle Related Function A signal enters CN2-9 of the controller and ACC of the motor driver from ACC key switch. (24V) The controller and the driver sense that the key switch is ON, when this signal enters.
Page 128 Electrics Section C Section C 4 - 5 Engine Control (CAPS II) 4 - 5 General (continued) Throttle Related Function (continued) For the Throttle motor to rotate to the position required by the throttle volume, an instruction from (CN8-4) to rotate counter clockwise is sent from the controller to the motor driver, and when received, sends a counter clockwise pulse from the motor driver to the throttle motor.
Page 129 Electrics Section C Section C 4 - 6 Engine Control (CAPS II) 4 - 6 General (continued) Controller Rotational Instructions After key switch ON When the transistor on the CW side of the controller is turned ON, 5V from a driver circuit drops to ground. At this point the CW line is 0V and CCW line is 5V at the driver side.
Page 130 Electrics Section C Section C 4 - 7 Engine Control (CAPS II) 4 - 7 1 Stop Motor Function With the key switch in the ON position, the power flows through relay and energises the actuating coil of relay 2 Key Switch ON which supplies current to rotate the stop motor.
Page 131 Electrics Section C Section C 4 - 8 Engine Control (CAPS II) 4 - 8 2 Emergency Stop Button ON The coil of relay 1 is excited when the emergency stop button is pressed when the key switch is ON (previous section A), and the relay switch turns to the lower position.
Page 132 Electrics Section C Section C 4 - 9 Engine Control (CAPS II) 4 - 9 Redundancy (Back-up) Throttle Control If the throttle control does not operate due to a controller defect, press the redundancy switch. When pressing the redundancy switch, control power supply to the controller is turned OFF, and the manual throttle circuit is activated.
Page 133 Electrics Section C Section C 4 - 10 Engine Control (CAPS II) 4 - 10 4 Automatic Engine Speed Adjustment To give accurate control, store the required RPM setting on the controller by carrying out the automatic engine adjustment procedure. This will be necessary after fitting a new controller or throttle motor or after adjusting/replacing the control link between the engine and throttle motor.
Page 134 Electrics Section C Section C 4 - 11 Engine Control (CAPS II) 4 - 11 5 Idling Control Time Chart With the key switch ON pressing the one-touch switch causes the switch lamp to come on. One-touch idle operation is possible when in one-touch idling mode regardless of whether the pilot pressure...
Page 135 Electrics Section C Section C 4 - 12 Engine Control (CAPS II) 4 - 12 6 Revolution Control for Each Mode The machine is in the standard mode when the key switch is ON. This position is 100 rpm less than the FULL rotational position (H mode).
Page 136 Electrics Section C Section C 4 - 13 Engine Control (CAPS II) 4 - 13 Control of Engine Speed for Breaker Operation Note: It is necessary to preset the engine r.p.m. to a speed which delivers the flow rate required for breaker operation (see Setting Function under Self Test Function).
Page 137 Electrics Section C Section C 4 - 14 Engine Control (CAPS II) 4 - 14 8 Engine Automatic Warm-up Time Chart Conditions for automatic warming up Water temperature is less than 50°C. Upper Pilot pressure switch is OFF. (attachment is not operating.) Lower Pilot pressure switch is OFF.
Page 138 Electrics Section C Section C 4 - 15 Engine Control (CAPS II) 4 - 15 Detection of Throttle Motor Assembly Defect (Out-of-step) Fault When the pulse signal cannot be interrupted by the driver, and deviates from regular rotation. Possible Factors If the adjusting screw of the throttle link is loosened, and the length of the link is changed more than the deflection of the spring.
Page 139 Electrics Section C Section C 5 - 1 Hydraulic System Control (CAPS II) 5 - 1 Summary of Hydraulic System Functions For more information about the electrically controlled functions listed below, refer to the detailed descriptions on the following pages. Each detailed description is identified by the same number as that used below. The supply current to Pump control depends on work such electromagnetic proportional...
Page 140 Electrics Section C Section C 5 - 2 Hydraulic System Control (CAPS II) 5 - 2 Summary of Hydraulic System Functions (continued) For more information about the electrically controlled functions listed below, refer to the detailed descriptions on the following pages.
Page 141 In the H mode, engine RPM is raised and current value is variable between Imax and Imin. This utilises maximum output of the engine. The S, L, and F modes have fixed current values. Current value of each mode Mode Machine Imax Imin Type JS330 520 mA 405 mA 410 mA 0 + 10 mA 0 + 10 mA 9803/6420 Issue 2*...
Page 142 Electrics Section C Section C 5 - 4 Hydraulic System Control (CAPS II) 5 - 4 Pump Control (continued) Performance Data Torque Ts=0.9TT TL=0.7TT Horsepower Flow Horsepower Electric current value I max. H MODE Pressure Revolution Target (At H mode max. revolutions) S MODE: Pump torque equals 90% of engine target torque T, IS is the constant current value.
Page 143 Electrics Section C Section C 5 - 5 Hydraulic System Control (CAPS II) 5 - 5 Pump Control (continued) Flow Chart 9803/6420 Issue 2*...
Page 144 Electrics Section C Section C 5 - 6 Hydraulic System Control (CAPS II) 5 - 6 Boom Lowering Speed Regulation Circuit Diagram Time Chart Flow Chart Regulating the speed of the boom lowering procedure is activated only in L, F mode. When changing to L, F mode, a transistor in the controller turns ON, and switches a solenoid valve.
Page 145 Electrics Section C Section C 5 - 7 Hydraulic System Control (CAPS II) 5 - 7 Cushioned Boom Starting Circuit Diagram Time Chart Even though travel limit and boom lowering switches are ON, pulse to solenoid valve does not go ON. When the boom lowering pressure switch turns ON, the solenoid valve switches on for 0.4 sec, and pilot pressure is sent to the negative control signal port of the pump.
Page 146 Electrics Section C Section C 5 - 8 Hydraulic System Control (CAPS II) 5 - 8 Cushioned Boom Starting (continued) Flow Chart 9803/6420 Issue 2*...
Page 147 Electrics Section C Section C 5 - 9 Hydraulic System Control (CAPS II) 5 - 9 Pressure Increasing System (One-touch digging force UP, Travel power UP) In only H or S modes, when the one-touch digging force UP switch is turned ON (IN5), the signal enters the controller through the timer in the panel switch and remains for 8 sec, 24V is output from the controller to the now activated solenoid valve.
Page 148 Electrics Section C Section C 5 - 10 Hydraulic System Control (CAPS II) 5 - 10 Pressure Increasing System (continued) L Mode Even though the one-touch digging force UP switch is pressed, the voltage is not output to the solenoid valve, and a pressure increase is not obtained.
Page 149 Electrics Section C Section C 5 - 11 Hydraulic System Control (CAPS II) 5 - 11 Pressure Increasing System (continued) Flow Chart 9803/6420 Issue 2*...
Page 150 Electrics Section C Section C 5 - 12 Hydraulic System Control (CAPS II) 5 - 12 3-Speed Travel and Max. Flow (Q) Cut Travelling at middle speed (always middle speed as At middle speed travel the key is switched ON). Travel motor swash plate: low side Even though travel and upper pressure switches are ON, Pump: Standard...
Page 151 Electrics Section C Section C 5 - 13 Hydraulic System Control (CAPS II) 5 - 13 5 3-Speed Travel and Max. Flow (Q) Cut (continued) Q cut is done by F mode using the ON signal of upper 1 At middle speed travel pressure S/W for the first time.
Page 152 Electrics Section C Section C 5 - 14 Hydraulic System Control (CAPS II) 5 - 14 3-Speed Travel and Max. Flow (Q) Cut (continued) Relation of Travel Mode and Motor Swash Plate, Pump Flow (Q) Cut Relation of Travel Mode and Motor Swash Plate, Pump flow (Q) Cut High Speed Middle Speed Low Speed Work mode is independent.
Page 153 Electrics Section C Section C 5 - 15 Hydraulic System Control (CAPS II) 5 - 15 3-Speed Travel and Max. Flow (Q) Cut (continued) Flow Chart 9803/6420 Issue 2*...
Page 154 Electrics Section C Section C 5 - 16 Hydraulic System Control (CAPS II) 5 - 16 6 Cushion (Soft/Hard) Switch Circuit Diagram Time Chart Flow Chart Output to the soft/hard solenoid valve is OFF when key switch is ON. This is its SOFT status. After the engine is started, the signal received from the panel switch is altered.
Page 155 Electrics Section C Section C 5 - 17 Hydraulic System Control (CAPS II) 5 - 17 Power Supply Cut Delay Circuit Diagram Time Chart When the signal (IN1) from the key switch is turned OFF, 24V from OUT 3 is output from the controller for 3 seconds. After 3 seconds the output of OUT 3 stops, and power to the coil from the electric battery relay is cut, contacts on the electric battery relay break, and the power supply is cut.
Page 156 Electrics Section C Section C 5 - 18 Hydraulic System Control (CAPS II) 5 - 18 Power Supply Cut Delay (continued) Flow Chart 9803/6420 Issue 2*...
Page 157 Electrics Section C Section C 5 - 19 Hydraulic System Control (CAPS II) 5 - 19 Swing Brake/Swing Lock a Swing Brake (i) Engine is running and swing lever is in neutral (50% brake). SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever...
Page 158 Electrics Section C Section C 5 - 20 Hydraulic System Control (CAPS II) 5 - 20 Swing Brake/Swing Lock (continued) a Swing Brake (continued) (ii) Engine is running and swing lever operation (brake release) Pressure Switch SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor...
Page 159 Electrics Section C Section C 5 - 21 Hydraulic System Control (CAPS II) 5 - 21 Swing Brake/Swing Lock (continued) b Swing Lock (Swing Lock Switch ON, 100% Brake) SOL: 2 Swing Swing lock SOL:1 SOL: 3 Monitor lever 100% lock brake Shut off ( P )
Page 160 Electrics Section C Section C 5 - 22 Hydraulic System Control (CAPS II) 5 - 22 Swing brake/Swing lock (continued) c Swing Brake (continued) Flow Chart 9803/6420 Issue 2*...
Page 161 Electrics Section C Section C 5 - 23 Hydraulic System Control (CAPS II) 5 - 23 Lever Lock Circuit Diagram Time Chart 9803/6420 Issue 2*...
Page 162 Electrics Section C Section C 5 - 24 Hydraulic System Control (CAPS II) 5 - 24 Lever Lock (continued) Flow Chart 9803/6420 Issue 2*...
Page 163 Electrics Section C Section C 5 - 25 Hydraulic System Control (CAPS II) 5 - 25 10 Travel Warning Circuit Diagram A travel pilot pressure switch is turned ON by travel lever operation and 24V is output for 10 seconds to the buzzer. 9803/6420 Issue 2*...
Page 164 Electrics Section C Section C 5 - 26 Hydraulic System Control (CAPS II) 5 - 26 11 Overload Protection Power Transistor Protection Controller Position Spare Spare High Dump Swing shut off solenoid V Lever lock solenoid V Travel alarm Pressure raising solenoid V Free swing solenoid V Negative control solenoid V Spare...
Page 165 Electrics Section C Section C 5 - 27 Hydraulic System Control (CAPS II) 5 - 27 12 Display Monitor a Radiator Water Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off.
Page 166 Electrics Section C Section C 5 - 28 Hydraulic System Control (CAPS II) 5 - 28 12 Display Monitor (continued) b Hydraulic Oil Temperature Circuit Diagram Overheat switch position and the ON signal of the thermostat sensor are OR processed and number 8 is lit. Overheat switch position and the OFF signal of the thermostat sensor are AND processed and number 8 turns off.
Page 167 Electrics Section C Section C 5 - 29 Hydraulic System Control (CAPS II) 5 - 29 12 Display Monitor (continued) c Fuel Remaining Circuit Diagram FUEL REMAINING RESISTANCE (litres) (OHM) MONITOR 284~ 13~10 243~284 21~13 200~243 27~21 158~200 34~27 115~158 44~34 72~115 59~44...
Page 168 Electrics Section C Section C 5 - 30 Hydraulic System Control (CAPS II) 5 - 30 12 Display Monitor (continued) d Warning Display (Message Display) START Message Display Key SW ON Key SW ON & Engine Running ! Battery charging Deficient ! Overheat ! Engine oil pressure down ! Electric system abnormality...
Page 169 Electrics Section C Section C 5 - 31 Hydraulic System Control (CAPS II) 5 - 31 13 High Dump Circuit Diagram A Panel switch B Boom raising pressure switch C High dump solenoid valve Timing Chart 9803/6420 Issue 2*...
Page 170 Electrics Section C Section C 5 - 32 Hydraulic System Control (CAPS II) 5 - 32 13 High Dump (continued) Flow Chart 9803/6420 Issue 2*...
Page 171 Electrics Section C Section C 6 - 1 *Throttle Motor (CAPS II) 6 - 1 Throttle Motor and Throttle Link Replacement Prepare the machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the throttle motor and link See Component Location Diagram in Routine Maintenance.
Page 172 Electrics Section C Section C 6 - 2 *Throttle Motor (CAPS II) 6 - 2 Throttle Motor and Throttle Link Replacement (continued) Installation of the throttle link lever a Install the lever on the new throttle motor without forcing it. b Coat the screws D with threadlocker before fastening.
Page 173 Electrics Section C Section C 6 - 3 Throttle Motor (CAPS II) 6 - 3 Automatic Adjustment Always perform the automatic adjustment when the controller and or the throttle motor or linkage is replaced. The controller must be programmed to suit the machine model. There are differences in the controller’s programming for various models and territories.
Page 174 Repeatedly press S Mode switch until the monitor’s Repeatedly press L Mode switch until ‘E’ is displayed on desired language is displayed on the mode screen. the clock (1st digit). All other displays are for non-JCB applications and are therefore not applicable. Mode...
Page 175 Electrics Section C Section C 7 - 1 Revolution Sensor 7 - 1 Revolution Sensor Removal and Installation Prepare the Machine Position the machine on level ground. Stop the engine and remove the starter key. Locate the Flywheel housing a The flywheel housing is machined to accommodate the sensor.
Page 176 Electrics Section C Section C 8 - 1 Self Test (CAPS II) 8 - 1 Self Test Function This series of vehicles contains numerous sensors to enable the machine to perform its own self test diagnosis. Below is a list of functions which are monitored by the system.
Page 177 TIME is displayed in the CLOCK display. WORK MODE Self-check Change Pattern MODE Select Reset CLOCK When the CHANGE switch is pressed the Country and Model designation is displayed: Message 301 = JS330 CH: MN WORK MODE Self-check Change MODE CLOCK 9803/6420 Issue 2*...
Page 178 Electrics Section C Section C 8 - 3 Self Test (CAPS II) 8 - 3 Self Test Function (continued) ENGINE RPM The Self Check items can be displayed by pressing the Message SELECT SWITCH after every singular display in the following order.
Page 179 Electrics Section C Section C 8 - 4 Self Test (CAPS II) 8 - 4 Self Test Function (continued) FUEL SENSOR RESISTANCE VALUE Message Pressing SELECT changes the display as shown. CH : FS The fuel sensor resistance is shown in Ohms in the clock display.
Page 180 Electrics Section C Section C 8 - 5 Self Test (CAPS II) 8 - 5 Self Test Function (continued) PRESSURE SWITCH INPUT Message Start engine. Pressing SELECT changes the display as shown. CH : PS This monitors pressure switch information in the clock display. WORK MODE 0 =Switch open Self-check...
Page 181 Electrics Section C Section C 8 - 6 Self Test (CAPS II) 8 - 6 Self Test Function (continued) Setting Function This section deals with setting separate parameters: Breaker engine speed. Automatic idle time. In addition to the previous sections displays, the following switches are used.
Page 182 CLOCK Message Machine Hammermaster Engine Normal flow EA: B ( RPM ) l/min JS330 1340 20 Seconds WORK MODE JS330 1490 Self-check MODE Reset When the desired RPM is shown, press and hold the RESET switch for 20 seconds to enter the setting into the controller.
Page 183 Electrics Section C Section C 8 - 8 Self Test (CAPS II) 8 - 8 Self Test Function (continued) Message When the desired AUTOMATIC IDLE TIME is reached, press EA: AI: ( RPM ) and hold the RESET switch for 20 seconds to enter the setting into the controller.
Page 184 Electrics Section C Section C 9 - 1 Fault Finding (CAPS II) 9 - 1 Fault Diagnosis This section is designed to simplify the Task of Fault Finding. When a message is displayed, the description of the fault is shown and the Problem No. is shown; this in turn then relates to the relevant page showing the Problem No.
Page 185 Electrics Section C Section C 9 - 2 Fault Finding (CAPS II) 9 - 2 Fault Diagnosis (continued) This explains how to trouble shoot in the event that the message does not go out even though suitable measures are taken to check and clear the problem.
Page 186 Electrics Section C Section C 9 - 3 Fault Finding (CAPS II) 9 - 3 Fault Diagnosis (continued) Judgement Item Value Measure 1. Fuel amount check Refuel 2. Inspection for fuel contaminant Clean, drain 3. Hydraulic oil amount check Refill oil 4.
Page 187 Electrics Section C Section C 9 - 4 Fault Finding (CAPS II) 9 - 4 Fault Diagnosis (continued) Emergency Engine Stop, Problem No.1 Note: Even if the emergency stop button is pressed the message does not go out. Prior Confirmation Items The "MODE"...
Page 188 Electrics Section C Section C 9 - 5 Fault Finding (CAPS II) 9 - 5 Fault Diagnosis (continued) Refuel, Problem No.2 Note: Message does not go out even if refuelled Prior Confirmation Items The "MODE" of the mode display is not flashing. Fuel bar graph displays one.
Page 189 Electrics Section C Section C 9 - 6 Fault Finding (CAPS II) 9 - 6 Fault Diagnosis (continued) Coolant Refill, Problem No 3 Note: Message does not go out even if coolant is refilled Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 190 Electrics Section C Section C 9 - 7 Fault Finding (CAPS II) 9 - 7 Fault Diagnosis (continued) Air Cleaner clogged, Problem No. 5 Note: Message does not go out even if the filter is renewed. Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 191 Electrics Section C Section C 9 - 8 Fault Finding (CAPS II) 9 - 8 Fault Diagnosis (continued) Low Engine Oil Pressure. Problem No. 6 Note: Message does not go out even if engine oil is satisfactory. Prior Confirmation Items The "MODE"...
Page 192 Electrics Section C Section C 9 - 9 Fault Finding (CAPS II) 9 - 9 Fault Diagnosis (continued) Engine Oil Filter Blocked, Problem No 7 Note: Message does not go out even if the engine oil filter is replaced and the oil is satisfactory. Prior Confirmation Items The "MODE"...
Page 193 Electrics Section C Section C 9 - 10 Fault Finding (CAPS II) 9 - 10 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 Note: Message does not go out even if the actual temperature is below the following; Hydraulic Oil Temperature 84°C. Engine Coolant Temperature 92°C.
Page 194 Electrics Section C Section C 9 - 11 Fault Finding (CAPS II) 9 - 11 Fault Diagnosis (continued) Fluid Overheating, water, oil, Problem No 8 (continued) Note: Message does not go out even if the actual Temperature is below the following:- Hydraulic Oil Temperature 84°C Engine Coolant Temperature 92°C Troubleshoot...
Page 195 Electrics Section C Section C 9 - 12 Fault Finding (CAPS II) 9 - 12 Fault Diagnosis (continued) Battery Charging, Problem No 9 Note: Message does not go out. Prior Confirmation Items The "MODE" of the mode display is not flashing. Troubleshoot Cause Remedy...
Page 196 Electrics Section C Section C 9 - 13 Fault Finding (CAPS II) 9 - 13 Fault Diagnosis (continued) Electrical Systems, Message Fault, Problem No 10 Note: Message does not go out. 9803/6420 Issue 2*...
Page 197 Electrics Section C Section C 9 - 14 Fault Finding (CAPS II) 9 - 14 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No. 10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Key switch ON Replace When transistor When electro Electro-magnetic electro...
Page 198 Electrics Section C Section C 9 - 15 Fault Finding (CAPS II) 9 - 15 Fault Diagnosis (continued) Electrical System, Message Fault, Problem No.10 (continued) Note: Message does not go out. Troubleshoot Cause Remedy Continued from previous page Remove driver connector Breakage or defective CN15 and measure wiring between...
Page 199 Electrics Section C Section C 9 - 16 Fault Finding (CAPS II) 9 - 16 Fault Diagnosis (continued) Engine Trouble, Problem No 11 Note: Engine does not start even though the message "electrical system abnormal" is not displayed. Prior Confirmation Items No abnormalities in engine or fuel system.
Page 200 Electrics Section C Section C 9 - 17 Fault Finding (CAPS II) 9 - 17 Fault Diagnosis (continued) Engine Trouble, Problem No 11 (continued) Troubleshoot Cause Remedy Key switch ON Engine system Inspect Is fuel cut lever on stop side Abnormality engine system.
Page 201 Electrics Section C Section C 9 - 18 Fault Finding (CAPS II) 9 - 18 Fault Diagnosis (continued) Engine Problem, Problem No 12 Note: Engine revolutions do not change with throttle volume control. Prior Confirmation Items The message "Engine emergency stop" is not displayed. Troubleshoot Cause Remedy...
Page 202 Electrics Section C Section C 9 - 19 Fault Finding (CAPS II) 9 - 19 Sensor Resistance Value Water temperature (Oil temperature) Minimum Maximum 20°C 8.00kû 10.20kû 30°C 5.35kû 6.50kû 40°C 3.60kû 4.55kû 50°C 2.50kû 3.10kû 60°C 1.70kû 2.20kû 70°C 1.20kû...
Page 203 Electrics Section C Section C 10 - 1 Wiper Motor 10 - 1 Windscreen Wiper Motor The windscreen wiper motor used on JS Machines has two nuts that must be set to the correct torque figure. Torque figures Item kgf m 12 -15 8.8 -11.0 1.2 -1.5...
Page 204 Page No. Technical Data JS330 1 - 1 JS450/JS460 1 - 3 Schematics Schematic Hydraulic Circuit JS330 3 - 1 Schematic Hydraulic Circuit JS450 3 - 3 Pilot Control Line Schematic 3 - 5 Schematic Hydraulic Circuit JS460 3 - 6...
Page 205 Section E Hydraulics Section E Contents Page No. Circuit Descriptions JS 330 - continued - Slew Brake 35 - 13 - Slew Lock 35 - 15 - Combined Slew and Dipper Closing 35 - 17 Excavator End Functions - Boom Up 35 - 21 - Boom Down 35 - 23...
Page 206 45 - 1 Dismantling and Assembly 46 - 1 Shuttle Valve Introduction 55 - 1 General Information 55 - 2 Slew Brake Valve JS330 Introduction, Technical Data 60 - 1 Operation 60 - 3 8 Spool Solenoid 65 - 1 Hydraulic Rams...
Page 207 Section E Hydraulics Section E Pumps Contents Page No. Slew Motor JS330 Specifications 83 - 1 Hydraulic Motor Components 83 - 2 Motor Operating Principles 83 - 3 Slew Brake Operation 83 - 4 Dismantling 92 - 1 Inspection 92 - 2...
Page 208 Hydraulics Section E Section E 1 - 1 Technical Data (JS330) 1 - 1 Note: For full specification details see information in each section. Pump Type Twin variable displacement piston pump Displacement Volume 134.6 cm /rev (8.2 in /rev )
Page 209 Hydraulics Section E Section E 1 - 2 Technical Data (JS330) 1 - 2 Travel Equipment Motor Fixed displacement piston motor (automatic 2-speed change) Suction Capacity 153.4/102.4 cm /rev (9.4/6.25 in /rev) Working Pressure 319 bar (326 kgf/cm Working Flow 276 l/min (60.7 gal/min)
Page 210 Hydraulics Section E Section E 1 - 3 Technical Data (JS450/460) 1 - 3 Note: For full specification details see information in each section. Pump Type Twin variable displacement piston pump Displacement Volume 170 cm /rev (8.2 in /rev ) x 2 Working Pressure 325 bar (331 kgf/cm Maximum Output...
Page 211 Hydraulics Section E Section E 3 - 1 Schematics 3 - 1 Schematic Hydraulic Circuit JS330 Safety Valve Solenoid Valve (optional) Check Valve (optional) Restrictor (optional) Holding Valve (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Rotary Coupling...
Page 213 Hydraulics Section E Section E 3 - 3 Schematics 3 - 3 Schematic Hydraulic Circuit JS450 Safety Valve Solenoid Valve (optional) Check Valve (optional) Restrictor (optional) Holding Valve (optional) Slew Motor Slew Reduction Gears Dipper Ram Traction Motor Traction Reduction Gear Rotary Coupling Bucket Ram Left Boom Ram...
Page 215 Hydraulics Section E Section E 3 - 5 Schematics 3 - 5 Pilot Control Line Schematic Hose Colour Code Component Ports/Services BL - blue A1 - Bucket close BR - brown Boom down CL - clear Bucket open green Boom up GR - grey Pump pressure...
Page 217 Hydraulics Section E Section E 3 - 6 Schematics 3 - 6 Schematic Hydraulic Circuit JS460 Directional Valve (optional) Relief Valve (optional) Bucket Ram Return Filter (optional) Left Boom Ram Right Boom Ram Track Motor Track Gearbox Rotary Coupling Dipper Ram Hose Burst Check valve (optional) Hose Burst Check valve (optional) Slew Motor...
Page 218 Section E Hydraulics Section E 3 - 7 Schematics 3 - 7 JS 460 Hydraulic Schematic 331/23322 iss 1 A382140 9803/6420 Issue 1...
Page 219 Section E Hydraulics Section E 3 - 8 3 - 8 Schematic Hydraulic Circuit JS330/JS460 Tier 2 The item numbers in the following list are identified on the Hydraulic schematic. Description Part No. Bucket Ram KTV 1021 Boom Ram Left Hand...
Page 221 Hydraulics Section E Section E 4 - 1 Pressure Testing - JS330 4 - 1 Pressure Measuring Points Pressure Relief Valves JS09450 Main relief valve Boom raise relief valve Boom lower relief valve Dipper out relief valve Dipper in relief valve...
Page 222 Hydraulics Section E Section E 4 - 2 Pressure Testing - JS330 4 - 2 Main Relief Valve (MRV) Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 223 Hydraulics Section E Section E 4 - 3 Pressure Testing - JS330 4 - 3 Accumulator Prepare the Machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground. Operate the dipper out and lower the boom to set the bucket on the ground.
Page 224 Hydraulics Section E Section E 4 - 4 Pressure Testing - JS330 4 - 4 Pilot Relief Valve Prepare the Machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 225 Hydraulics Section E Section E 4 - 5 Pressure Testing - JS330 4 - 5 Slew Motor Relief Valve Prepare the machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 226 Hydraulics Section E Section E 4 - 6 Pressure Testing - JS330 4 - 6 Auxiliary Relief Valves General The auxiliary relief valves (ARV’s) are set to a higher pressure than the main relief valve (MRV). To permit pressure testing of the ARV’s it is necessary to temporarily adjust the MRV to a higher setting (refer to view B on page 4 - 1).
Page 227 Hydraulics Section E Section E 4 - 7 Pressure Testing - JS330 4 - 7 Auxiliary Relief Valves (continued) Boom Ram Prepare the machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 228 Hydraulics Section E Section E 4 - 8 Pressure Testing - JS330 4 - 8 Auxiliary Relief Valves (continued) Dipper Ram Prepare the Machine. a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 229 Hydraulics Section E Section E 4 - 9 Pressure Testing - JS330 4 - 9 Auxiliary Relief Valves (continued) Bucket Ram Prepare the Machine a Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 230 Hydraulics Section E Section E 4 - 10 Pressure Testing - JS330 4 - 10 Travel Motor Relief Valves Note: The travel motor relief valves are set to a higher pressure than the main relief valve (MRV). To permit pressure testing of the travel motor relief valves it is necessary to temporarily adjust the MRV to a higher setting.
Page 231 Hydraulics Section E Section E 4 - 11 Pressure Testing - JS330 4 - 11 Hydraulic Pump Proportional Pressure Reduction Valve Prepare the Machine Put the operator levers into neutral and lower the gate lock lever. Start the engine and park the machine on level ground.
Page 232 Section E Hydraulics Section E 5 - 1 Pressure Testing- JS450/JS460 5 - 1 Pressure Testing - General Confirmation of the oil Temperature Confirm the oil temperature is between 45° - 55° C using a Operate the bucket control slowly until it reaches one thermometer.
Page 233 Section E Hydraulics Section E 5 - 2 Pressure Testing- JS450/JS460 5 - 2 PORT Pm1 AND Pm2 Q MAX CUT HOSES PORT Pi2 PUMP 2 NEGATIVE CONTROL PORT Pi1 PUMP 1 NEGATIVE CONTROL PORT PB1 AND PB2 NOT USED - CONNECTED TO TANK A387080 JS460 Pump Hose Connections...
Page 234 Hydraulics Section E Section E 5 - 3 Pressure Testing JS 330/JS 450 5 - 3 Pressure Testing Main Excavator Services JS 330/JS 450 JSJS11190 Fit test gauges ( 0 - 600 bar ) into hose connections to ports MA1 + MA2 Warm up machine hydraulic temperature to 50 °C Port MA1 Port MA2...
Page 235 Hydraulics Section E Section E 5 - 4 Pressure Testing (JS330) 5 - 4 Testing Horsepower Control JS 330 / JS 450 VIEW OF HYDRAULIC PUMP Proportional solenoid secondary pressure measurement port Brown/Black (BrB) Brown/Black (BrB) A326250 Fit gauge ( 0 - 60 bar ) into proportional solenoid...
Page 236 Hydraulics Section E Section E 5 - 5 Technical Data (JS450) 5 - 5 Test Max Flow Signal - JS 330/JS 450 Port SC JSJS11190 Fit test gauge ( 0 - 60 bar ) to port SC with tee piece adapter. Warm up machine hydraulic temperature to 50 °C.
Page 237 Hydraulics Section E Section E 5 - 6 Technical Data (JS450) 5 - 6 Testing Negative Control Signal - JS 330/JS 450 JSJS11190 Fit test gauges ( 0 - 60 bar ) into hose connections to ports PZ1 + PZ1 with tee piece adapter Warm up machine hydraulic temperature to 50 °C Port PZ1 Port PZ2...
Page 238 Hydraulics Section E Section E 10 - 1 Hydraulic Pump/Regulator - JS330/JS450 10 - 1 Introduction The pump/regulator consists of two variable displacement type axial piston pumps (P1 and P2) supplying pressurised oil to operate machine functions, plus a gear type pilot pump (Pp) to provide pilot circuit pressure for operator control of machine functions.
Page 239 Hydraulics Section E Section E 10 - 2 Hydraulic Pump/Regulator - JS330/JS450 10 - 2 JS09380 Port Identification Port Function Port Function Main pumps (P1 and P2) suction port Pilot pressure port Pump P1 delivery port Q maximum cut pressure port...
Page 240 Hydraulics Section E Section E 10 - 3 Hydraulic Pump/Regulator - JS330/JS450 10 - 3 Operation Pilot Pump (P3) Main Pumps (P1 and P2) Three pumping elements are contained within this unit, P3 is The pilot pump D is driven from the pump input shaft B via a a gear driven eccentric rotor pump which supplies servo 1 : 0.8 ratio speed increasing gear.
Page 241 Section E Hydraulics Section E 11 - 1 Hydraulic Pump/Regulator - JS330/JS460 11 - 1 Introduction JS330/JS460 The pump/regulator consists of two variable displacement type axial piston pumps (P1 and P2) supplying pressurised oil to operate machine functions, plus a gear type pilot pump (Pp) to provide pilot circuit pressure for operator control of machine functions.
Page 242 Section E Hydraulics Section E 11 - 2 Hydraulic Pump/Regulator - JS330/JS460 11 - 2 Hydraulic Pump JS460 i1 i2 B1 B2 m1 m2 GEAR PUMP A370400 Port Identification Port Function Port Function Delivery Port Tank Delivery Port Tank Gear Pump Delivery Port...
Page 243 Section E Hydraulics Section E 11 - 3 Hydraulic Pump/Regulator - JS330/JS460 11 - 3 Hydraulic Pump JS330/JS460 FLOW FLOW FLOW r1.r2 GEAR PUMP PB1 and PB2 TANK A370410 Pi1 and Pi2 NEGATIVE CONTROL Pm1 and Pm2 Q MAX CUT...
Page 244 Section E Hydraulics Section E 11 - 4 Hydraulic Pump/Regulator - JS330/JS460 11 - 4 Operation Pump regulator - JS460 and 330 tier 2 For this description pump 2 has been used. On start up swash piston B is held in the maximum flow position by the spring force of A and by servo pressure which enters via check valve H.
Page 245 Section E Hydraulics Section E 11 - 5 Hydraulic Pump/Regulator - JS460 11 - 5 19 18 A370930 9803/6420 Issue 1...
Page 246 Section E Hydraulics Section E 11 - 6 Hydraulic Pump/Regulator - JS460 11 - 6 Hydraulic Pump Dismantling and Assembly The working environment must be clean and the workbench covered with a cloth or rubber sheet to prevent damage to the components.
Page 247 Section E Hydraulics Section E 11 - 7 Hydraulic Pump/Regulator - JS460 11 -7 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove the gear pump from pump casing 1. Remove booster cover 4, booster 5 and cover 6. Remove socket head screws 7, 8, 9 to release valve cover 10.
Page 248 Section E Hydraulics Section E 11 - 8 Hydraulic Pump/Regulator - JS460 11 - 8 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) From pump casing 1 remove both assemblies comprising cylinder 24, pistons 25, set plate 26, spherical bush 27 and cylinder springs 28. Take care not to damage the sliding surfaces of all components.
Page 249 Section E Hydraulics Section E 11 -9 Hydraulic Pump/Regulator - JS460 11 - 9 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove snap ring 37 and front cover 38, complete with O-ring 38A, from front casing 39. Discard the O-ring. Note 5: Use a flat blade screwdriver via the slot in the outer circumference of the drive shaft aperture to ease out front cover 38.
Page 250 Section E Hydraulics Section E 11 -10 Hydraulic Pump/Regulator - JS460 11 - 10 Hydraulic Pump (cont’d) Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove both snap rings 49 and both bearing spacer 50. Remove drive shaft 11 and driven shaft 12 by gently tapping them out complete with support bearings 54, bearing spacers 53 and snap rings 51, 51A (shaft 11) or snap rings 52, 52A (shaft 12).
Page 251 56 (refer to Dismantling, step 19). Fit the swash plate supports 56 to pump casing 1. Secure with cap screws 55, the threads smeared with JCB Threadlocker and Sealer, tightened to a torque of 29 Nm (21 lbf ft). A371020...
Page 252 Section E Hydraulics Section E 11 - 12 Hydraulic Pump/Regulator - JS330/JS460 11 - 12 Hydraulic Pump (cont’d) Assembly (cont’d) Fit spacer 47A, drive gear 48 and spacer 47 to drive shaft 11. Secure with snap ring 46. Fit driven gear 45 and spacer 44 to driven shaft 12.
Page 253 11 - 13 Hydraulic Pump (cont’d) Assembly (cont’d) Apply JCB Threadlocker and Sealer to the threaded portions of servo pistons 33 and tilting pins 34. Use a protector when tightening the parts to prevent damage to the tilting pinhead and the feedback pin.
Page 254 Section E Hydraulics Section E 11 - 14 Hydraulic Pump/Regulator - JS330/JS460 11 - 14 Hydraulic Pump (cont’d) Assembly (cont’d) Grease new O-rings 18, 19, 20 and new flange seal 21 and fit to the mounting flange of pump casing 1.
Page 255 Section E Hydraulics Section E 11 - 15 Hydraulic Pump/Regulator - JS330/JS460 11 - 15 Hydraulic Pump (cont’d) Assembly (cont’d) Fit cover 6, booster 5 and booster cover 4 to valve cover 10. Fit the gear pump to pump casing 1.
Page 256 Hydraulics Section E Section E 12 - 1 Hydraulic Pump/Regulator 12 - 1 Fault finding As a first step towards locating a fault, carry out the following checks. Check the hydraulic filter for the presence of excessive foreign materials. The nature of the foreign materials could yield a clue as to the source of damage or wear.
Page 257 Hydraulics Section E Section E 12 - 2 Hydraulic Pump/Regulator 12 - 2 Fault finding (cont’d) Symptom Possible cause Remedy Pressure does not increase. Relief valve setting low. Reset relief valve. Switching valve, actuator leakage Renew switching valve, actuator. increase. Pump displacement efficiency Renew pump.
Page 258 Hydraulics Section E Section E 14 - 1 *Hydraulic Pump/Regulator JS330/JS450 14 - 1 Dismantling/Assembly Before attempting to dismantle the hydraulic pump, drain all The following procedures show a complete strip down, but, oil, blank all inlet and outlet ports and wash the outer unless absolutely necessary, avoid disturbing or dismantling surfaces with a suitable solvent to remove all dirt and dust.
Page 259 Hydraulics Section E Section E 14 - 2 *Hydraulic Pump/Regulator JS330/JS450 14 - 2 Dismantling (cont’d) Separating the Sub-Assemblies (continued) Position a rubber disc A on top of each cylinder block and lightly secure with bolts B (M6 x 30) to retain the cylinder blocks in their current situations.
Page 260 Hydraulics Section E Section E 14 - 3 *Hydraulic Pump/Regulator JS330/JS450 14 - 3 Dismantling (cont’d) Control Section In both positions in turn, press spring seat B down to release retaining ring A. Remove the retaining ring. Remove spring seat B, outer control spring C, shim D and inner control spring E.
Page 261 Hydraulics Section E Section E 14 - 4 *Hydraulic Pump/Regulator JS330/JS450 14 - 4 Dismantling (cont’d) Control Section (continued) Note: Repeat steps 12 to 23 for both positions on the directional control valve/control section housing. Remove control plate A and swash plate B.
Page 262 Hydraulics Section E Section E 14 - 5 *Hydraulic Pump/Regulator JS330/JS450 14 - 5 Dismantling (cont’d) JS09030 9803/6420 Issue 2*...
Page 263 Hydraulics Section E Section E 14 - 6 *Hydraulic Pump/Regulator JS330/JS450 14 - 6 Dismantling (cont’d) Regulator Remove the three socket head screws A and lift off secondary throttle valve B. Unscrew restrictor (orifice) C and remove O-ring D. Using a spanner on the large hexagon, unscrew guide E and take out spring F, distance piece G and spool H.
Page 264 Hydraulics Section E Section E 14 - 7 *Hydraulic Pump/Regulator JS330/JS450 14 - 7 Dismantling (cont’d) Main Housing Remove snap ring A. Use a flat screwdriver around the edge of oil seal B to prise it loose and then remove it.
Page 265 Hydraulics Section E Section E 14 - 8 *Hydraulic Pump/Regulator JS330/JS450 14 - 8 Inspection All parts should be checked for signs of damage or wear, paying particular attention to the parts detailed below. Part Renew if these conditions exist Piston assembly Any sliding part is deeply scratched or has a rough surface.
Page 266 Hydraulics Section E Section E 14 - 9 *Hydraulic Pump/Regulator JS330/JS450 14 - 9 Assembly Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and renew as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.
Page 267 Reverse ‘Dismantling’ step 39 after applying grease to Reverse ‘Dismantling’ steps 6 and 5. Apply JCB Multi- the inner lip of the oil seal and JCB Threadlocker and Gasket to the flange and then fit a new pre-formed Sealer to the plug.
Page 268 Hydraulics Section E Section E 20 - 1 Regulator JS330/JS460 20 - 1 Specifications Displacement 97.2 (96.5) cc/rev Revolving Speed Range Rated 2070 (2200) rev/min Pressure Rated 320 (320) kgf/cm Max 350 (350) kgf/cm Maximum Flow Rate 201 (211) l/min (Rated revolution load pressure 80 Kgf/cm...
Page 269 Hydraulics Section E Section E 21 - 1 Regulator JS330/JS460 21 - 1 Operation Refer to the sectional drawings at the beginning of this section. The regulator consists of the following control mechanisms: Horsepower control. Automatically reduces the pump swash angle (delivery flow) according to the increase in P pump delivery pressure and P pump delivery pressure and limits the input torque to below a preset value.
Page 270 Hydraulics Section E Section E 21 - 2 Regulator JS330/JS460 21 - 2 PROPORTIONAL PRESSURE REDUCING VALVE ALLOWABLE RANGE OF CURRENT-PRESSURE PROFILE • Primary press. 40 kgf/cm (38.6 bar, 568.8 lb/in • Flow in port A 0 l/min • Fluctuation of proportional...
Page 271 Hydraulics Section E Section E 22 - 1 Regulator JS330/JS460 22 - 1 Regulator Trouble Shooting Engine Overloads Put a load on each pump to determine if the front or rear pump is malfunctioning. If both pumps are abnormal, check 1 and 2.
Page 272 Hydraulics Section E Section E 23 - 1 Regulator JS330/JS460 23 - 1 9803/6400 Issue 1...
Page 273 23 - 2 Regulator JS330/JS460 23 - 2 Regulator Dismantling For JS330 Tier 2 and JS460 machines Refer to the exploded drawing at the beginning of this section. Before dismantling, blank all inlet and outlet ports and wash the outer surfaces with a suitable solvent to remove all dirt and dust.
Page 274 Hydraulics Section E Section E 23 - 3 Regulator JS330/JS460 23 - 3 Regulator Dismantling (continued) 3 After removing the cover (629) assembly, remove the outer spring (625), inner spring (626), spring base (624) from the compensatory part and pull out the adjusting ring (645), pilot spring (646), spring base (644) from the pilot part.
Page 275 Hydraulics Section E Section E 23 - 4 Regulator JS330/JS460 23 - 4 Regulator Dismantling (continued) Remove the locking ring (858) and remove the fulcrum plug (614) and adjusting plug (615). Note: For easy removal, use M6 bolt to pull out the fulcrum plug (614) and adjusting plug (615).
Page 276 Hydraulics Section E Section E 23 - 5 Regulator JS330/JS460 23 - 5 Regulator Dismantling (continued) 8 Pull out pin (874) and remove the feedback lever (611). Note: To remove the pin (874), use a slim steel bar and push out from above taking care not to touch the lever (612).
Page 277 Hydraulics Section E Section E 23 - 6 Regulator JS330/JS460 23 - 6 Regulator Assembly All tapped holes and gasket faces should be thoroughly degreased by washing as liquid packing and adhesive is Clean each part in a suitable solvent and dry using used on all gasket surfaces and threads.
Page 278 Hydraulics Section E Section E 23 - 7 Regulator JS330/JS460 23 - 7 Regulator Assembly (continued) Insert the pin, which is press-fitted into the lever (613), into the pilot piston groove and assemble lever. Assemble the fulcrum plug so that the pin, which is press-fitted in the fulcrum plug, is inserted in the lever pin hole.
Page 279 Hydraulics Section E Section E 23 - 8 Regulator JS330/JS460 23 - 8 Regulator Assembly (continued) 10 Assemble the set spring (655) into the spool hole and the compensatory piston (621) and piston case (622) into the compensatory hole. Install the pilot cover (641) and tighten with hexagonal socket head bolts (436) (438).
Page 281 Hydraulics Section E Section E 31 - 1 Control Valve 31 - 1 Precautions Before Use Installation Ensure that excessive force is not put on the valve by the piping. Tighten the installation bolts to the specified torque. Take care when welding work is done near the valve, excessive heat can damage the seals.
Page 282 Section E Section E 32 - 1 Control Valve 32 - 1 Spool Location - JS330 AM1, AM2 = Dipper rams = Bucket ram BM1, BM2 = Boom rams = Auxiliary supply to attachment (if fitted) = Slew motor supply...
Page 283 Hydraulics Section E Section E 32 - 2 Control Valve 32 - 2 Hydraulic Circuit Diagram - JS330 9803/6420 Issue 1...
Page 284 Hydraulics Section E Section E 32 - 3 Control Valve 32 - 3 Control Valve JS450/JS460 - Spool Location 9803/6420 Issue 1...
Page 285 Hydraulics Section E Section E 32 - 4 Control Valve 32 - 4 Hydraulic Circuit Diagram - JS450/JS460 5P.P2 5Dr2 5Pa1 5Pb1 5Pa1 SWING 5Pb1 5Pb2 ARM(2) 4Pb4 5Pb2 5Pb2 4Pa4 ARM (1) 4Dr1 BOOM(1) 5Dr1 4Pb3' 4P.P1 4Pb3 BOOM (2) 4Pa3 5P.P1 4Pb2'...
Page 286 Section E Hydrualics Section E 32 - 5 Control Valve 32 - 5 Hydraulic Circuit Diagram - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 DIPPER 2 OPTION BUCKET DR2' BOOM2 BOOM1 SLEW TRAVEL LINEAR TRAVEL TRAVEL 9803/6420 Issue 1*...
Page 287 Section E Hydraulics Hydraulics Section E 32 - 6 Circuit Description 32 - 6 Control Valve JS460 Tier 2 Spool Location pa10 pa11 (DR2') DR1' ARM2 BUCKET BOOM2 BOOM1 SWING DR2' TRAVEL TRAVEL STRAIGHT TRAVEL A408810 Issue 1* 9808/6420...
Page 288 Hydraulics Section E Section E 33 - 1 *Control Valve - JS 330 33 - 1 Operation The illustrations referred to in the following descriptions are When one side of ‘travel left’ TL [or ‘travel right’ TR] grouped together at the end of the Operation set of pages. spool is switched (Figures 1-4), the signal lands 8, 9 [ 10, 11] are closed, but the oil from signal port Pp Where a descriptive text applies to more than one circuit, the...
Page 289 Hydraulics Section E Section E 33 - 2 *Control Valve - JS 330 33 - 2 Operation (continued) Individual Operation (continued) Boom Spool (continued) Dipper Spool Lower Boom (see Figure 8) Dump (2-speed confluence) (see Figure 10) When port PRb3 is pressurised and the ‘boom 1’ Port PLa4 is pressurised to switch the ‘dipper 1’...
Page 290 Hydraulics Section E Section E 33 - 3 *Control Valve - JS 330 33 - 3 Operation (continued) Individual Operation (continued) Priority Circuits Boom Priority (see Figures 1, 2 and 17) Relief Valves During combined operation of swivel and boom, Main Relief Valve (see Figures 4 and 14) the poppet 27 is held in its seated (closed) state The oil from port P1 flows through load check...
Page 291 Hydraulics Section E Section E 33 - 4 *Control Valve - JS 330 33 - 4 Figure 1 9803/6420 Issue 2*...
Page 292 Hydraulics Section E Section E 33 - 5 *Control Valve - JS 330 33 - 5 9803/6420 Issue 2*...
Page 293 Hydraulics Section E Section E 33 - 6 *Control Valve - JS 330 33 - 6 (Fig 6 Figure 3 Figure 4 9803/6420 Issue 2*...
Page 294 Hydraulics Section E Section E 33 - 7 *Control Valve - JS 330 33 - 7 Figure 5 Figure 6 9803/6420 Issue 2*...
Page 295 Hydraulics Section E Section E 33 - 8 *Control Valve - JS 330 33 - 8 Figure 7 Figure 8 9803/6420 Issue 2*...
Page 296 Hydraulics Section E Section E 33 - 9 *Control Valve - JS 330 33 - 9 Figure 9 9803/6420 Issue 2*...
Page 297 Hydraulics Section E Section E 33 - 10 Control Valve - JS 330 33 - 10 Figure 10 9803/6420 Issue 2*...
Page 298 Hydraulics Section E Section E 33 - 11 *Control Valve - JS 330 33 - 11 Figure 11 Figure 12 9803/6420 Issue 2*...
Page 299 Hydraulics Section E Section E 33 - 12 *Control Valve - JS 330 33 - 12 Figure 13 Figure 14 9803/6420 Issue 2*...
Page 300 Hydraulics Section E Section E 33 - 13 *Control Valve - JS 330 33 - 13 Figure 15 Figure 16 9803/6420 Issue 2*...
Page 301 Hydraulics Section E Section E 33 - 14 *Control Valve - JS 330 33 - 14 Figure 17 9803/6420 Issue 2*...
Page 302 Hydraulics Section E Section E 33 - 15 *Control Valve - JS 330 33 - 15 Figure 18 - 1 Figure 18 - 2 Figure 18 - 3 9803/6420 Issue 2*...
Page 303 Hydraulics Section E Section E 34 - 1 Control Valve 34 - 1 Removal and Replacement -Typical Removal ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Page 304 Hydraulics Section E Section E 34 - 2 Control Valve - JS 450/460 34 - 2 Figure 1 9803/6420 Issue 1...
Page 305 Hydraulics Section E Section E 34 - 3 Control Valve - JS 450/460 34 - 3 Operation The illustrations referred to in the following descriptions are grouped together at the end of the Operation set of pages. Auxiliary (OPT) Spool (see Figure 5) When port 5Pa4 [ 5Pb4] is pressurised and auxiliary Where a descriptive text applies to more than one circuit, the spool OPT is switched, neutral passage A is closed...
Page 306 Hydraulics Section E Section E 34 - 4 Control Valve - JS 450/460 34 - 4 9803/6420 Issue 1...
Page 307 Hydraulics Section E Section E 34 - 5 Control Valve - JS 450/460 34 - 5 Operation (continued) Individual Operation (continued) Boom Spool (continued) Lower Boom (see Figure 8) Crowd (2-speed confluence) (see Figure 11) When port 4Pa3 is pressurised and the ‘boom 1’ Port 5Pa2 is pressurised to switch the ‘dipper 1’...
Page 308 Hydraulics Section E Section E 34 - 6 Control Valve - JS 450/460 34 - 6 Figure 3 Figure 4 9803/6420 Issue 1...
Page 309 Hydraulics Section E Section E 34 - 7 Control Valve - JS 450/460 34 - 7 Operation (continued) Individual Operation (continued) Priority Circuits Boom Priority (see Figures 1, 2 and 15) Relief Valves During combined operation of swing and boom Main Relief Valve (see Figures 4 and 13) UP, the poppet [14] is held in its seated (closed) The oil from port 5P flows through the 5 spool...
Page 310 Hydraulics Section E Section E 34 - 8 Control Valve - JS 450/460 34 - 8 Figure 5 BUCKET SERVICE Figure 6 9803/6420 Issue 1...
Page 311 Hydraulics Section E Section E 34 - 9 Control Valve - JS 450/460 34 - 9 Figure 7 9803/6420 Issue 1...
Page 312 Hydraulics Section E Section E 34 - 10 Control Valve - JS 450/460 34 - 10 Figure 8 9803/6420 Issue 1...
Page 313 Hydraulics Section E Section E 34 - 11 Control Valve -JS 450/460 34 - 11 BOOM 1 BOOM 2 Figure 9 9803/6420 Issue 1...
Page 314 Hydraulics Section E Section E 34 - 12 Control Valve - JS 450/460 34 - 12 Figure 10 9803/6420 Issue 1...
Page 315 Hydraulics Section E Section E 34 - 13 Control Valve - JS 450/460 34 - 13 Figure 11 Figure 12 9803/6420 Issue 1...
Page 316 Hydraulics Section E Section E 34 - 14 Control Valve - JS 450/460 34 - 14 Figure 13 Figure 14 9803/6420 Issue 1...
Page 317 Hydraulics Section E Section E 34 - 15 Control Valve - JS 450/460 34 - 15 Figure 15 Figure 16 9803/6420 Issue 1...
Page 318 Hydraulics Section E Section E 35 - 1 Circuit Descriptions - JS330 35 - 1 9803/6420 Issue 2*...
Page 319 Hydraulics Section E Section E 35 - 2 Circuit Descriptions - JS330 35 - 2 Travel Functions High Speed The 2-step swash plate angle of the travel motors G and H is shifted to the minimum slant angle to facilitate high speed travel.
Page 320 Hydraulics Section E Section E 35 - 3 Circuit Descriptions - JS330 35 - 3 9803/6420 Issue 2*...
Page 321 Hydraulics Section E Section E 35 - 4 Circuit Descriptions - JS330 35 - 4 Travel Functions (continued) Middle Speed This is the normal travel pattern. When the key switch is set to OFF and then set to ON again, the travel mode adopted is always middle speed, irrespective of the speed selected before switching off.
Page 322 Hydraulics Section E Section E 35 - 5 Circuit Descriptions - JS330 35 - 5 9803/6420 Issue 2*...
Page 323 Hydraulics Section E Section E 35 - 6 Circuit Descriptions - JS330 35 - 6 Travel Functions (continued) Low Speed Maximum flow rate of the hydraulic pump is cut in the low speed mode and speed is decreased. Pressurised oil from port A1 (front pump) enters port P1 of control valve A.
Page 324 Hydraulics Section E Section E 35 - 7 Circuit Descriptions - JS330 35 - 7 9803/6420 Issue 2*...
Page 325 Hydraulics Section E Section E 35 - 8 Circuit Descriptions - JS330 35 - 8 Travel Functions (continued) Linear Travel When performing travel and attachment operation or travel and slew operation at the same time, this function maintains linearity. For example, consider travel at middle speed and boom down operation.
Page 326 Hydraulics Section E Section E 35 - 9 Circuit Descriptions - JS330 35 - 9 9803/6420 Issue 2*...
Page 327 Hydraulics Section E Section E 35 - 10 Circuit Descriptions - JS330 35 - 10 Slew Functions Zero Slewing The slew mechanical brake is maintained at 50% when the engine is running. An electrical signal is sent from controller B to slew brake solenoid valve L2 part of slew brake valve L, and the solenoid valve is energised.
Page 328 Hydraulics Section E Section E 35 - 11 Circuit Descriptions - JS330 35 - 11 9803/6420 Issue 2*...
Page 329 Hydraulics Section E Section E 35 - 12 Circuit Descriptions - JS330 35 - 12 Slew Functions (continued) Slew Operation Before slew operation, the slew mechanical brake is maintained at 50%. In performing slew operations the mechanical brake is released and normal slew movement is possible.
Page 330 Hydraulics Section E Section E 35 - 13 Circuit Descriptions - JS330 35 - 13 9803/6420 Issue 2*...
Page 331 Hydraulics Section E Section E 35 - 14 Circuit Descriptions - JS330 35 - 14 Slew Functions (continued) Slew Brake Five seconds after the slew brake lever is returned to neutral, the slew mechanical brake is applied at 50%. When the slew lever is returned to neutral, the slew spool returns to the neutral state.
Page 332 Hydraulics Section E Section E 35 - 15 Circuit Descriptions - JS330 35 - 15 9803/6420 Issue 2*...
Page 333 Hydraulics Section E Section E 35 - 16 Circuit Descriptions - JS330 35 - 16 Slew Functions (continued) Slew Lock The slew mechanical brake is applied at 100% when the slew lock switch (see W) is ON and slewing will not take place even if the slew lever is operated.
Page 334 Hydraulics Section E Section E 35 - 17 Circuit Descriptions 35 - 17 9803/6420 Issue 2*...
Page 335 Hydraulics Section E Section E 35 - 18 Circuit Descriptions - JS330 35 - 18 Slew Functions (continued) Combined Slew and Dipper Closing (Slew Priority) When operating the slew mechanism and dipper simultaneously, as in bank shaving or cutting operations,...
Page 336 Hydraulics Section E Section E 35 - 19 Circuit Descriptions - JS330 35 - 19 Slew Functions (continued) Reverse Protection Valves The Reverse Protection Valve is integral with the slew motor and prevents the superstructure ‘springing’ back when slewing is stopped.
Page 337 INTENTIONALLY LEFT BLANK...
Page 338 Hydraulics Section E Section E 35 - 20 Circuit Descriptions - JS330 35 - 20 9803/6420 Issue 2*...
Page 339 Hydraulics Section E Section E 35 - 21 Circuit Descriptions - JS 330 35 - 21 Excavator End Functions Boom Up Pressurised oil from port A2 (rear pump) enters port P2 of control valve A. Pressurised oil from port A1 (front pump) enters port P1 of the control valve.
Page 340 Hydraulics Section E Section E 35 - 22 Circuit Descriptions - JS 330 35 - 22 9803/6420 Issue 2*...
Page 341 Hydraulics Section E Section E 35 - 23 Circuit Descriptions - JS 330 35 - 23 Excavator End Functions (continued) Boom Down Pressurised oil from port A2 (rear pump) enters port P2 of control valve A. Operation of the boom down control directs pilot pressure oil into port PRb3 of the control valve to switch boom 1 spool BM1.
Page 342 Hydraulics Section E Section E 35 - 24 Circuit Descriptions - JS 330 35 - 24 9803/6420 Issue 2*...
Page 343 Hydraulics Section E Section E 35 - 25 Circuit Descriptions - JS 330 35 - 25 Excavator End Functions (continued) Boom Down in L, F Mode When L or F mode is selected, an electrical signal is sent from controller B to the boom down speed regulation solenoid valve C5 of 8-spool solenoid valve C.
Page 344 Hydraulics Section E Section E 35 - 26 Circuit Descriptions - JS 330 35 - 26 9803/6420 Issue 2*...
Page 345 Hydraulics Section E Section E 35 - 27 Circuit Descriptions - JS 330 35 - 27 Excavator End Functions (continued) Boom Down Starting Delay The boom down delay circuit provides machine shock protection for 0.4 seconds of the boom down operation. The pressure switch installed on port C3 of shuttle block R is operated by the pilot pressure oil from the boom lowering control.
Page 346 Hydraulics Section E Section E 35 - 28 Circuit Descriptions - JS 330 35 - 28 9803/6420 Issue 2*...
Page 347 Hydraulics Section E Section E 35 - 29 Circuit Descriptions - JS 330 35 - 29 Excavator End Functions (continued) Dipper Opening Pressurised oil from port A1 (front pump) enters port P1 of control valve A. Pressurised oil from port A2 (rear pump) enters port P2 of the control valve.
Page 348 Hydraulics Section E Section E 35 - 30 Circuit Descriptions - JS 330 35 - 30 Detail of spool AM1 9803/6420 Issue 2*...
Page 349 Hydraulics Section E Section E 35 - 31 Circuit Descriptions - JS 330 35 - 31 Excavator End Functions (continued) Dipper Closing Pressurised oil from port A1 (front pump) enters port P1 of control valve A. Pressurised oil from port A2 (rear pump) enters port P2 of the control valve.
Page 350 Hydraulics Section E Section E 35 - 32 Circuit Descriptions - JS 330 35 - 32 9803/6420 Issue 2*...
Page 351 Hydraulics Section E Section E 35 - 33 Circuit Descriptions - JS 330 35 - 33 Excavator End Functions (continued) Bucket Opening Pressurised oil from port A1 (front pump) enters port P1 of control valve A. Pressurised oil from port A2 (rear pump) enters port P2 of the control valve.
Page 352 Hydraulics Section E Section E 35 - 34 Circuit Descriptions - JS 330 35 - 34 9803/6420 Issue 2*...
Page 353 Hydraulics Section E Section E 35 - 35 Circuit Descriptions - JS 330 35 - 35 Excavator End Functions (continued) Bucket Closing Pressurised oil from port A1 (front pump) enters port P1 of control valve A. Pressurised oil from port A2 (rear pump) enters port P2 of the control valve.
Page 354 Hydraulics Section E Section E 35 - 36 Circuit Descriptions - JS 330 35 - 36 9803/6420 Issue 2*...
Page 355 Hydraulics Section E Section E 35 - 37 Circuit Descriptions - JS 330 35 - 37 Excavator End Functions (continued) Combined Operations - Bucket Closing + Boom Up Bucket spool closing side stroke regulation is done by pilot pressure of boom up, suppressing flow to the bucket side and improving boom up during multiple operations.
Page 356 Hydraulics Section E Section E 35 - 38 Circuit Descriptions - JS 330 35 - 38 9803/6420 Issue 2*...
Page 357 Hydraulics Section E Section E 35 - 39 Circuit Descriptions - JS 330 35 - 39 Excavator End Functions (continued) Cushion Valve - Soft During boom operations (up and down) and dipper operations (open and close), when the operation control lever is returned to neutral, cushion valve Y, with a heat circuit, reduces the shock to the machine when the boom or dipper stop moving.
Page 358 Hydraulics Section E Section E 35 - 40 Circuit Descriptions - JS 330 35 - 40 9803/6420 Issue 2*...
Page 359 Hydraulics Section E Section E 35 - 41 Circuit Descriptions - JS 330 35 - 41 Excavator End Functions (continued) Cushion Valve - Hard Overrides the cushion function of cushion valve Y and improves soil removal from the attachment. When the soft/hard switch (see D) is switched to the hard side, the soft/hard solenoid valve is energised by electrical signals from controller B to 8-spool solenoid valve C.
Page 360 Hydraulics Section E Section E 35 - 42 Circuit Descriptions - JS 330 35 - 42 9803/6420 Issue 2*...
Page 361 Hydraulics Section E Section E 35 - 43 Circuit Descriptions - JS 330 35 - 43 Excavator End Functions (continued) High Dump During simultaneous slew and boom up operation, operation of boom up priority spool aa in the slew feed line restricts the flow to the slew motor thereby increasing the flow to the boom up line and increasing the speed of boom up.
Page 362 Hydraulics Section E Section E 35 - 44 Circuit Descriptions - JS 330 35 - 44 Pump Control Maximum Flow Rate Cut The maximum flow rate of the pump is cut during low speed Pressure line travel in H, S, L, F mode, during attachment operation in F Return line mode or during swing operation.
Page 363 INTENTIONALLY LEFT BLANK...
Page 364 Hydraulics Section E Section E 35 - 46 Circuit Descriptions - JS 330 35 - 46 9803/6420 Issue 2*...
Page 365 Hydraulics Section E Section E 35 - 47 Circuit Descriptions - JS 330 35 - 47 Pump Control (continued) Negative Control For energy saving purposes, the flow output rate of one or both the hydraulic pumps during no-load running is minimised by application of negative control, thereby reducing fuel consumption.
Page 366 Hydraulics Section E Section E 35 - 48 Circuit Descriptions - JS 330 35 - 48 & £ 382240 9803/6420 Issue 1...
Page 367 35 - 49 Circuit Descriptions - JS 330 35 - 49 JS330 Hammer/Auxiliary/Merge Solenoid 3 is also energised allowing a path to the to the boom 2 down spool and to the merge logic valve. When the The auxiliary circuits on this machine are activated by the...
Page 368 Section E Hydraulics Section E 36 - 1 Circuit Descriptions - JS450, JS460 36 - 1 9803/6420 Issue 1*...
Page 369 Section E Hydraulics Section E 36 - 2 Circuit Descriptions - JS450, JS460 36 - 2 Travel Functions High Speed The 2-step swash plate angle of the travel motors G and H is shifted to the minimum slant angle to facilitate high speed travel.
Page 370 Section E Hydraulics Section E 36 - 3 Circuit Descriptions - JS450, JS460 36 - 3 9803/6420 Issue 1*...
Page 371 Section E Hydraulics Section E 36 - 4 Circuit Descriptions - JS450, JS460 36 - 4 Travel Functions (continued) Middle Speed This is the normal travel pattern. When the engine start switch is set to OFF and then set to ON again, the travel mode adopted is always middle speed, irrespective of the speed selected before switching off.
Page 372 Section E Hydraulics Section E 36 - 5 Circuit Descriptions - JS450, JS460 36 - 5 9803/6420 Issue 1*...
Page 373 Section E Hydraulics Section E 36 - 6 Circuit Descriptions - JS450, JS460 36 - 6 Travel Functions (continued) Low Speed Maximum flow rate of the hydraulic pump is cut in the low speed mode and speed is decreased. Pressurised oil from port A1 (upper pump) enters port 5P of control valve A.
Page 374 Section E Hydraulics Section E 36 - 7 Circuit Descriptions - JS450, JS460 36 - 7 9803/6420 Issue 1*...
Page 375 Section E Hydraulics Section E 36 - 8 Circuit Descriptions - JS450, JS460 36 - 8 Travel Functions (continued) Linear Travel When performing travel and attachment operation or travel and slew operation at the same time, this function maintains linearity. For example, consider travel at middle speed and swing operation.
Page 376 Section E Hydraulics Section E 36 - 9 Circuit Descriptions - JS450, JS460 36 - 9 9803/6420 Issue 1*...
Page 377 Section E Hydraulics Section E 36 - 10 Circuit Descriptions - JS450, JS460 36 - 10 Slew Functions Zero Slewing The slew mechanical brake is maintained at 50% when the engine is running. An electrical signal is sent from controller B to slew brake solenoid valve L2 part of slew brake valve L, and the solenoid valve is energised.
Page 378 Section E Hydraulics Section E 36 - 11 Circuit Descriptions - JS450, JS460 36 - 11 9803/6420 Issue 1*...
Page 379 Section E Hydraulics Section E 36 - 12 Circuit Descriptions - JS450, JS460 36 - 12 Slew Functions (continued) Slew Operation Before slew operation, the slew mechanical brake is maintained at 50%. In performing slew operations the mechanical brake is released and normal slew movement is possible.
Page 380 Section E Hydraulics Section E 36 - 13 Circuit Descriptions - JS450, JS460 36 - 13 9803/6420 Issue 1*...
Page 381 Section E Hydraulics Section E 36 - 14 Circuit Descriptions - JS450, JS460 36 - 14 Slew Functions (continued) Slew Brake Five seconds after the slew brake lever is returned to neutral, the slew mechanical brake is applied at 50%. When the slew lever is returned to neutral, the slew spool returns to the neutral state.
Page 382 Section E Hydraulics Section E 36 - 15 Circuit Descriptions - JS450, JS460 36 - 15 9803/6420 Issue 1*...
Page 383 Section E Hydraulics Section E 36 - 16 Circuit Descriptions - JS450, JS460 36 - 16 Slew Functions (continued) Slew Lock The slew mechanical brake is applied at 100% when the slew lock switch (see W) is ON and slewing will not take place even if the slew lever is operated.
Page 384 Section E Hydraulics Section E 36 - 17 Circuit Descriptions - JS450, JS460 36 - 17 9803/6420 Issue 1*...
Page 385 Section E Hydraulics Section E 36 - 18 Circuit Descriptions - JS450, JS460 36 - 18 Slew Functions (continued) Combined Slew and Dipper Closing (Slew Priority) When operating the slew mechanism and dipper simultaneously, as in bank shaving or cutting operations, slew priority is achieved by means of a restrictor regardless of the amount of the dipper work pressure, and the necessary slewing power can be achieved.
Page 386 Section E Hydraulics Section E 36 - 19 Circuit Descriptions - JS450, JS460 36 - 19 Slew Functions (continued) Reverse Protection Valve The Reverse Protection Valve is integral with the slew motor and prevents the superstructure ‘springing’ back when slewing is stopped. Zero slewing, slew start-up and during slewing The Reverse Protection Valve is in the neutral state (not actuated) as shown in Figure 1.
Page 387 Section E Hydraulics Section E 36 - 20 Circuit Descriptions - JS450, JS460 36 - 20 Slew Functions (continued) Reverse Protection Valve (continued) Slew acceleration during slew (Figure 2) After the motor stops, due to the relief valve braking action, it will tend to spring back due to the residual pressure.
Page 388 Section E Hydraulics Section E 36 - 21 Circuit Descriptions - JS450, JS460 36 - 21 9803/6420 Issue 1*...
Page 389 Section E Hydraulics Section E 36 - 22 Circuit Descriptions - JS450, JS460 36 - 22 Excavator End Functions Boom Up Pressurised oil from port A2 (lower pump) enters port 5P of control valve A. Pressurised oil from port A1 (upper pump) enters port 4P of the control valve.
Page 390 Section E Hydraulics Section E 36 - 23 Circuit Descriptions - JS450, JS460 36 - 23 9803/6420 Issue 1*...
Page 391 Section E Hydraulics Section E 36 - 24 Circuit Descriptions - JS450, JS460 36 - 24 Excavator End Functions (continued) Boom Down Pressurised oil from port A1 (upper pump) enters port 4P of control valve A. Operation of the boom down control directs pilot pressure oil into port 4Pa3 of the control valve to switch boom 1 spool BM1.
Page 392 Section E Hydraulics Section E 36 - 25 Circuit Descriptions - JS450, JS460 36 - 25 9803/6420 Issue 1*...
Page 393 Section E Hydraulics Section E 36 - 26 Circuit Descriptions - JS450, JS460 36 - 26 Excavator End Functions (continued) Boom Down in L, F Mode When L or F mode is selected, an electrical signal is sent from controller B to the boom down speed regulation solenoid valve C5 of 8-spool solenoid valve C.
Page 394 Section E Hydraulics Section E 36 - 27 Circuit Descriptions - JS450, JS460 36 - 27 9803/6420 Issue 1*...
Page 395 Section E Hydraulics Section E 36 - 28 Circuit Descriptions - JS450, JS460 36 - 28 Excavator End Functions (continued) Boom Down Starting Delay The boom down delay circuit provides machine shock protection for 0.4 seconds before boom down operation starts.
Page 396 Section E Hydraulics Section E 36 - 29 Circuit Descriptions - JS450, JS460 36 - 29 9803/6420 Issue 1*...
Page 397 Section E Hydraulics Section E 36 - 30 Circuit Descriptions - JS450, JS460 36 - 30 Excavator End Functions (continued) Dipper Opening Pressurised oil from port A1 (upper pump) enters port 5P of control valve A. Pressurised oil from port A2 (lower pump) enters port 4P of the control valve.
Page 398 Section E Hydraulics Section E 36 - 31 Circuit Descriptions - JS450, JS460 36 - 31 Detail of spool AM1 9803/6420 Issue 1*...
Page 399 Section E Hydraulics Section E 36 - 32 Circuit Descriptions - JS450, JS460 36 - 32 Excavator End Functions (continued) Dipper Closing Pressurised oil from port A1 (upper pump) enters port 5P of control valve A. Pressurised oil from port A2 (lower pump) enters port 4P of the control valve.
Page 400 Section E Hydraulics Section E 36 - 33 Circuit Descriptions - JS450, JS460 36 - 33 9803/6420 Issue 1*...
Page 401 Section E Hydraulics Section E 36 - 34 Circuit Descriptions - JS450, JS460 36 - 34 Excavator End Functions (continued) Bucket Opening Pressurised oil from port A2 (lower pump) enters port 4P of control valve A. Operation of the bucket open control directs pilot pressure oil into control valve port 4Pa2 and switches bucket spool BKT.
Page 402 Section E Hydraulics Section E 36 - 35 Circuit Descriptions - JS450, JS460 36 - 35 9803/6420 Issue 1*...
Page 403 Section E Hydraulics Section E 36 - 36 Circuit Descriptions - JS450, JS460 36 - 36 Excavator End Functions (continued) Bucket Closing Pressurised oil from port A2 (lower pump) enters port 4P of control valve A. Operation of the bucket close control directs pilot pressure oil into control valve port 4Pa2 and switches bucket spool BKT.
Page 404 Section E Hydraulics Section E 36 - 37 Circuit Descriptions - JS450, JS460 36 - 37 9803/6420 Issue 1*...
Page 405 Section E Hydraulics Section E 36 - 38 Circuit Descriptions - JS450, JS460 36 - 38 Excavator End Functions (continued) Combined Operations - Bucket Closing + Boom Up Bucket spool closing side stroke regulation is done by pilot pressure of boom up, suppressing flow to the bucket side and improving boom up during multiple operations.
Page 406 Section E Hydraulics Section E 36 - 39 Circuit Descriptions - JS450, JS460 36 - 39 9803/6420 Issue 1*...
Page 407 Section E Hydraulics Section E 36 - 40 Circuit Descriptions - JS450, JS460 36 - 40 Excavator End Functions (continued) High Dump During simultaneous slew and boom up operation, operation of boom up priority spool aa in the slew feed line restricts the flow to the slew motor thereby increasing the flow to the boom up line and increasing the speed of boom up.
Page 408 Section E Hydraulics Section E 36 - 41 Circuit Descriptions - JS450, JS460 36 - 41 Pump Control Maximum Flow Rate Cut The maximum flow rate of the pump is cut during low speed Pressure line travel in H, S, L, F mode, during attachment operation in F Return line mode or during swing operation.
Page 409 INTENTIONALLY LEFT BLANK...
Page 410 Section E Hydraulics Section E 36 - 42 Circuit Descriptions - JS450, JS460 36 - 42 9803/6420 Issue 1*...
Page 411 Section E Hydraulics Section E 36 - 43 Circuit Descriptions - JS450, JS460 36 - 43 Pump Control (continued) Negative Control For energy saving purposes, the flow output rate of one or both the hydraulic pumps during no-load running is minimised by application of negative control, thereby reducing fuel consumption.
Page 412 Section E Hydraulics Section E 36 - 44 Circuit Descriptions - JS450, JS460 36 - 44 £ 9803/6420 Issue 1*...
Page 413 Section E Hydraulics Section E 36 - 45 Circuit Descriptions - JS450, JS460 36 - 45 Hammer Circuit The auxiliary circuits on this machine are activated by the use of 3 solenoids controlled by the 3-position switch in the RHS console. When hammer mode is selected at 4 none of the 3 solenoid valves 1, 2, 3 are energised.
Page 414 Section E Hydraulics Section E 36 - 46 Circuit Descriptions - JS450, JS460 36 - 46 9803/6410 Issue 1*...
Page 415 Section E Hydraulics Section E 36 - 47 Circuit Descriptions - JS450, JS460 36 - 47 Crusher Circuit When the auxiliary selector 4 is switched to crusher, relay I R1 and solenoid valve 2 are energised. Pilot pressure from the remote control valve 5 enters the control valve A via ports A1 and 5Pb4 and switches the option spool 6.
Page 416 Hydraulics Section E Section E 37 - 1 Circuit Descriptions - JS460 37 - 1 Travel Circuit FEED P2 SWING ARM2 ARM1 BOOM1 BOOM2 SPOOL MOVED TRAVEL L ACROSS OPTION SERVO SERVO 4Pb1 PRESSURE PRESSURE TO 5Pb5 PORT 5A5 TRAVEL R PORT 5B5 TRAVEL FEED P1...
Page 417 Hydraulics Section E Section E 37 - 2 Circuit Descriptions - JS460 37 - 2 Travel Circuit Pressure from P1 Red (dashed) Pressure from P2 Pink Pressure switch circuit Green Tank line Orange Servo pressure When both travel pedals are selected pilot pressure from the travel pedals enters the valve block at ports 5Pb5 to select the main spool for RH travel and port 4Pb1 to select the main spool for LH travel.
Page 418 Hydraulics Section E Section E 37 - 3 Circuit Descriptions - JS460 37 - 3 Multi Function Travel and Boom Up FEED P2 SWING ARM2 TO BOOM ARM1 BOOM1 BOOM2 SPOOL SELECTED PORT 4Pb3 SPOOL SELECTED 4Pb2 OPTION TRAVEL L SERVO PRESSURE TO 4Pb1 EXCAVATOR TRAVEL R...
Page 419 Hydraulics Section E Section E 37 - 4 Circuit Descriptions - JS460 37 - 4 Multi Function Travel and Boom Up Pressure from P1 Red (dashed) Pressure from P2 Pink Pressure switch circuit Green Tank line Orange Servo pressure For the following example boom up and both travel spools have been selected.
Page 420 Hydraulics Section E Section E 37 - 5 Circuit Descriptions - JS460 37 - 5 Hammer/ Auxiliary/Merge Circuit - Hammer 9803/6410 Issue 1...
Page 421 Hydraulics Section E Section E 37 - 6 Circuit Descriptions - JS460 37 - 6 Hammer/ Auxiliary/Merge Circuit Hammer The auxiliary circuits on this machine are activated by the use of 4 solenoids controlled by the 3-position switch in the RHS console.
Page 422 Hydraulics Section E Section E 37 - 7 Circuit Descriptions - JS460 37 - 7 Hammer/ Auxiliary/Merge Circuit - Auxiliary 9803/6420 Issue 1...
Page 423 Hydraulics Section E Section E 37 - 8 Circuit Descriptions - JS460 37 - 8 Hammer/ Auxiliary/Merge Circuit Auxiliary If 2 way auxiliary is selected on the 3 position switch, then the hammer/auxiliary solenoid C) located under the cab is energised.
Page 424 Hydraulics Section E Section E 37 - 9 Circuit Descriptions - JS460 37 - 9 Hammer/ Auxiliary/Merge Circuit - Merge 9803/6420 Issue 1...
Page 425 Hydraulics Section E Section E 37 - 10 Circuit Descriptions - JS460 37 - 10 Hammer/ Auxiliary/Merge Circuit Merge When the merge position is selected on the 3-way switch all 4 solenoids will energise. Note: Solenoids B and D will only energise when the merge pressure switch is closed.
Page 426 Section E Hydraulics Section E 38 - 1 Circuit Description 38 - 1 Neutral Circuit - JS460 Tier 2 With all the controls in the neutral position, flow from pump A1 enters the main control valve 12 at port P1 and flow from pump A2 enters the main control valve 12 at port P2.
Page 427 Section E Hydraulics Hydraulics Section E 38 - 2 Circuit Description 38 - 2 Neutral Circuit - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 DIPPER 2 BUCKET 44 bar at 26 OPTION 10µ CC/rev 164.7 CC/rev DR2' i=1.032 170.0 CC/rev 1.03 bar i=1.0...
Page 428 Section E Hydraulics Hydraulics Section E 38 - 3 Circuit Description 38 - 3 Straight Line Travel - JS460 Tier 2 Key to Oil Flow & Pressure pa11 pa10 Full Pressure DR1' Pressure Servo Neutral Exhaust Cavitation DIPPER 1 Lock Up DIPPER 2 OPTION BUCKET...
Page 429 Section E Hydraulics Section E 38 - 4 Circuit Description 38 - 4 Straight Line Travel - JS460 Tier 2 (Travel and exavator services selected) Refer to Travel Middle Speed for servo function of travel circuit and Boom Up for servo function of Boom up function Dipper 1 spool Option spool...
Page 430 Section E Hydraulics Section E 38 - 5 Circuit Description 38 - 5 Travel - Middle Speed - JS460 Tier 2 When both tracks are selected, servo pressure from port 2 (LH travel lever),and port 4 (RH travel lever) 18 enters the main control valve 12 at Pb1 and Pa6 respectively, selecting Dipper 1 spool the left and right hand travel spools.
Page 431 Section E Hydraulics Hydraulics Section E 38 - 6 Circuit Description 38 - 6 Travel - Middle Speed - JS460 Tier 2 pa11 pa10 Key to Oil Flow & Pressure DR1' Full Pressure Pressure Servo Neutral Exhaust DIPPER 1 Cavitation Lock Up DIPPER 2 OPTION...
Page 432 Section E Hydraulics Hydraulics Section E 38 - 7 Circuit Description 38 - 7 Boom Up - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 380 bar 380 bar DIPPER 2 OPTION BUCKET DR2' BOOM2 BOOM1 SLEW TRAVEL BUCKET BOOM OPEN CLOSE DOWN...
Page 433 Section E Hydraulics Section E 38 - 8 Circuit Description 38 - 8 Boom Up - JS460 Tier 2 Servo pressure from the handcontroller 21 enters the servo shuttle valve 26 at port A3 and is disributed to: 1. Boom up pressure switch 25 at port S2 2.
Page 434 Section E Hydraulics Section E 38 - 9 Circuit Description 38 - 9 Boom Down - JS460 Tier 2 Servo pressure from the Handcontroller enters the Servo Shuttle valve 26 at port A4 and is disributed to: 1. Port S3 to activate the Boom down pressure switch 2.
Page 435 Section E Hydraulics Hydraulics Section E 38 - 10 Circuit Description 38 - 10 Boom Down - JS460 Tier 2 pa11 pa10 DR1' DIPPER 2 Fig 1 OPTION BUCKET DR2' BOOM2 BOOM1 SLEW TRAVEL Key to Oil Flow & Pressure Full Pressure LINEAR TRAVEL...
Page 436 Section E Hydraulics Hydraulics Section E 38 - 11 Circuit Description 38 - 11 Dipper Out - JS460 Tier 2 Key to Oil Flow & Pressure Full Pressure pa11 pa10 Pressure DR1' Servo Neutral Exhaust Cavitation BL E Lock Up DIPPER 1 DIPPER 2 OPTION...
Page 437 Section E Hydraulics Section E 38 - 12 Circuit Description 38 - 12 Dipper Out - JS460 Tier 2 Servo pressure from the Handcontroller 24 is sent to port A5 of the shuttle valve 26 and is disributed to: 1. Port C3 to port Pb9 of the Main control valve 12 to Dipper 1 spool activate the Dipper 2 spool.
Page 438 Section E Hydraulics Section E 38 - 13 Circuit Description 38 - 13 Dipper In - JS460 Tier 2 Servo pressure from the Hand controller 24 is sent to port A6 of the servo shuttle valve 26 and is dritributed to: Dipper 1 spool 1.
Page 439 Section E Hydraulics Hydraulics Section E 38 - 14 Circuit Description 38 - 14 Dipper In - JS460 Tier 2 Key to Oil Flow & Pressure Full Pressure Pressure Servo pa11 pa10 DR1' Neutral Exhaust Cavitation Lock Up BL E DIPPER 1 DIPPER 2 OPTION...
Page 440 Section E Hydraulics Hydraulics Section E 38 - 15 Circuit Description 38 - 15 Bucket Opening - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 DIPPER 2 OPTION BUCKET DR2' BOOM2 BOOM1 SLEW TRAVEL Key to Oil Flow & Pressure BUCKET BOOM LINEAR...
Page 441 Section E Hydraulics Section E 38 - 16 Circuit Description 38 - 16 Bucket Opening - JS460 Tier 2 Servo pressure from port 1 of the Handcontroller 21 selects the bucket spool open position via port Pa8 of the Main Dipper 1 spool control valve 12.
Page 442 Section E Hydraulics Section E 38 - 17 Circuit Description 38 - 17 Bucket Closing - JS460 Tier 2 Servo pressure from the handcontroller is sent from port 3 to port Pb8 of the Main control valve 12 and moves the Bucket Dipper 1 spool spool into the bucket close position.
Page 443 Section E Hydraulics Hydraulics Section E 38 - 18 Circuit Description 38 - 18 Bucket Closing - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 DIPPER 2 OPTION BUCKET DR2' BOOM2 BOOM1 SLEW TRAVEL LINEAR TRAVEL TRAVEL Key to Oil Flow & Pressure Full Pressure Pressure Servo...
Page 444 Section E Hydraulics Hydraulics Section E 38 - 19 Circuit Description 38 - 19 Priority Valves - JS460 Tier 2 Key to Oil Flow & Pressure Full Pressure Pressure A3 S2 Servo RIGHT DOWN LEFT Neutral BOOM Exhaust SWING Cavitation Lock Up pa11 pa10...
Page 445 Section E Hydraulics Section E 38 - 20 Circuit Description 38 - 20 Priority Valves - JS460 Tier 2 Swing over Dipper Priority (A) Dipper 1 spool This a non-selectable function automatically carried out Option spool within the Main controll valve 12 when Slew and Dipper are Boom 2 spool used together.
Page 446 Section E Hydraulics Section E 38 - 21 Circuit Description 38 - 21 Slew Circuit - JS460 Tier 2 Servo pressure from the Handcontroller 24 enters the Servo shuttle valve 26 at port A2 and is disributed to: Dipper 1 spool Option spool 1.
Page 447 Section E Hydraulics Hydraulics Section E 38 - 22 Circuit Description 38 - 22 Slew Circuit - JS460 Tier 2 SOFT/HARD LEVER LOCK 2-STAGE RELIEF MAX FLOW CUT pa11 pa10 NEGATIVE FLOW SWING SHUT OFF CON. DR1' BOOM PRIORITY OVER SWING 2-STAGE TRAVEL DIPPER 1 DIPPER 2...
Page 448 Section E Hydraulics Hydraulics Section E 38 - 23 Circuit Description 38 - 23 Auxiliary Flow/Merged - JS460 Tier 2 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust pa11 pa10 DR1' Cavitation Lock Up DIPPER 1 DIPPER 2 BUCKET OPTION...
Page 449 Section E Hydraulics Section E 38 - 24 Circuit Description 38 - 24 Auxiliary Flow - JS460 Tier 2 An auxiliary circuit gives a bi-directional flow to the equipment being used. Dipper 1 spool Option spool The Option pedal 19 can be selected back or forward Boom 2 spool depending on the direction the operator wants the Slew spool...
Page 450 Section E Hydraulics Section E 38 - 25 Circuit Description 38 - 25 Hammer circuit - JS460 Tier 2 The hammer function only works when the hammer pedal 19 is pressed in a forward direction. In this position pressure Dipper 1 spool from the foot pedal is available to the hammer pressure Option spool switch 16, to reduce engine RPM to supply the required oil...
Page 451 Section E Hydraulics Hydraulics Section E 38 - 26 Circuit Description 38 - 26 Hammer - JS460 Tier 2 pa11 pa10 DR1' DIPPER 1 DIPPER 2 BUCKET OPTION 10µ 3.5 bar DR2' BOOM2 BOOM1 SLEW TRAVEL LINEAR TRAVEL TRAVEL Key to Oil Flow & Pressure OPTION Full Pressure Pressure...
Page 453 Hydraulics Section E Section E 40 - 1 Remote Control Valve (Services) 40 - 1 Introduction This section deals with the Remote Control Valve which provides pilot pressure for slewing, boom/dipper and bucket operation. The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure reduction valves used to control the pilot pressure are located in the main housing.
Page 454 Hydraulics Section E Section E 40 - 2 Remote Control Valve (Services) 40 - 2 JS03240 JS03210 Item Description Qty. Item Description Qty. Item Description Qty. Lower body Seal Gaiter Upper body Plunger Roll pin ‘O’-ring Split washer Control handle ‘O’-ring Spring seat Locknut...
Page 455 Hydraulics Section E Section E 40 - 3 Remote Control Valve (Services) 40 - 3 Operation The assembly of the pilot pressure control valve is shown on page 40 - 2. The pressure reduction unit is comprised of spools 17, pressure control springs 14, return springs 15, spring seats 13 and split washers 12.
Page 456 Hydraulics Section E Section E 41 - 1 Remote Control Valve (Services) 41 - 1 Dismantling and Assembly Notes: All parts are precision made and require the utmost care when being handled. During dismantling, do not use excessive force to separate components which could cause scratches or burrs on bearing surfaces.
Page 457 Hydraulics Section E Section E 41 - 2 Remote Control Valve (Services) 41 - 2 Dismantling and Assembly (cont’d) Dismantling (cont’d) Remove mounting screws (4 off) and lift out control valve. Clean the valve exterior using approved solvent and using soft metal pads for protection, clamp the valve body into a vice.
Page 458 Hydraulics Section E Section E 41 - 3 Remote Control Valve (Services) 41 - 3 Dismantling and Assembly (cont’d) Assembly The numerical sequence given previously is a guide to dismantling. For assembly the sequence should be reversed noting the following details: Locate retaining plate 18 onto plunger guides 8 and using the jig, screw knuckle joint into position.
Page 459 Hydraulics Section E Section E 42 - 1 Remote Control Valve (Services) 42 - 1 Fault finding Symptom Possible cause Remedy Low secondary pressure. Primary pressure is low. Apply the correct primary pressure. Renew the spring. Spring 14 is damaged. Renew the remote control valve Clearance between the spool and assembly.
Page 461 Hydraulics Section E Section E 45 - 1 Remote Control Valve (Travel) 45 - 1 Introduction This section deals with the remote control valves which provide pilot pressure for the track drives. The valves are mounted centrally below the cab floor and are operated by either the control levers or the foot pedals. Specification Working pressure 45 kgf/cm...
Page 462 Hydraulics Section E Section E 46 - 1 Remote Control Valve (Travel) 46 - 1 JS09190 9803/6420 Issue 1...
Page 463 7.1. Tighten lock nuts 4.1. protect the housing from jaw inflicted damage. Tilt the rocker and apply JCB HP Grease to the top Remove items 4, 7 and 8 as assemblies. of the push rod revealed. Tilt the rocker the opposite way and grease the other push rod.
Page 464 Hydraulics Section E Section E 55 - 1 Shuttle Valve 55 - 1 Introduction The shuttle valve is incorporated into the main control circuit to act as a pilot signal diverter valve. Pressurised hydraulic oil, directed by the operator’s controls from the remote control valves to the main control valve is redirected by the shuttle valve to perform additional pilot control functions.
Page 465 Hydraulics Section E Section E 55 - 2 Shuttle Valve 55 - 2 General Information Key to illustrations: Port Connections Slew right Slew pressure switch Slew left Boom up pressure pwitch Boom raise Boom down pressure switch Boom lower Dipper out boost Bucket close Dipper in boost Bucket open...
Page 466 Hydraulics Section E Section E 60 - 1 Slew Brake Valve (JS330) 60 - 1 Introduction The valve is used to control the application and release of the slew brake at either 50% or 100% pressure. The valve is operated by pilot pressure selected by the operator’s control lever.
Page 467 Hydraulics Section E Section E 60 - 2 Slew Brake Valve (JS330) 60 - 2 Solenoid control valve (slew lock) Solenoid control valve (slew brake) Pressure reducing valve Waterproof, 2 pin electrical contact housing Power source Ground Protective tube (yellow)
Page 468 Hydraulics Section E Section E 60 - 3 Slew Brake Valve (JS330) 60 - 3 Operation Slew Brake Release Pilot pressure at 45 bar (652 lbf/in ) enters port P and is routed two ways. It flows firstly to pressure reducing valve 8, the output of which is fed back to oppose the pressure of its internal spring.
Page 469 Hydraulics Section E Section E 65 - 1 8 Spool Solenoid 65 - 1 8 Spool Solenoid B1 T1 For soft/hard For lever lock 2 stage relief For max flow cut For swing shut - off For boom lowering delay For high speed For boom lowering speed travel...
Page 471 Hydraulics Section E Section E 70 - 1 Hydraulic Rams 70 - 1 Specifications - for old XO machines JS330 JS450 Boom Ram Cylinder Inside Diameter: 140 mm (5.51 in) Cylinder Inside Diameter: 160 mm (6.30 in) Left & Right...
Page 472 If leaving for more than one week, apply anti-rust oil to the rod surface. Use genuine JCB parts when replacing parts. If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts. Caution during dismantling and reassembly.
Page 473 Hydraulics Section E Section E 72 - 1 Hydraulic Rams 72 - 1 Bucket Ram - Removal ! 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.
Page 474 Hydraulics Section E Section E 72 - 2 Hydraulic Rams 72 - 2 Bucket Ram - Removal (cont’d) Remove the nuts and bolts from the rod end of the ram. Push the pin out using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 475 Hydraulics Section E Section E 72 - 3 Hydraulic Rams 72 - 3 Bucket Ram - Removal (cont’d) Attach a sling to support the ram. Remove the nuts and bolts from the cylinder end of the ram. Push out the pin using a bar and hammer. Lift the ram clear.
Page 476 Hydraulics Section E Section E 72 - 4 Hydraulic Rams 72 - 4 Bucket Ram - Replacement (cont’d) Connect the hoses. Hoist the ram to align with the link. Install the pin, bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 477 Hydraulics Section E Section E 73 - 1 Hydraulic Rams 73 - 1 Dipper Ram - Removal ! 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.
Page 478 Hydraulics Section E Section E 73 - 2 Hydraulic Rams 73 - 2 Dipper Ram - Removal (cont’d) Remove the nuts and bolts from the rod end of the ram. Push out the pin, using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 479 Hydraulics Section E Section E 73 - 3 Hydraulic Rams 73 - 3 Dipper Ram - Removal (cont’d) Remove the grease tube. Attach a sling to support the ram. Remove the nuts and bolts from the cylinder end of the ram, push out the pin using a bar and hammer.
Page 480 Hydraulics Section E Section E 73 - 4 Hydraulic Rams 73 - 4 Dipper Ram - Replacement (cont’d) Install the pin, bolts and nuts. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins.
Page 481 Hydraulics Section E Section E 73 - 5 Hydraulic Rams 73 - 5 Dipper Ram - Replacement (cont’d) Install the pin, bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 482 Hydraulics Section E Section E 74 - 1 Hydraulic Rams 74 - 1 Boom Ram - Removal ! 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.
Page 483 Hydraulics Section E Section E 74 - 2 Hydraulic Rams 74 - 2 Boom Ram - Removal (cont’d) a Remove the nuts, bolt and collar. b Push out the pin, using a bar and hammer. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 484 Hydraulics Section E Section E 74 - 3 Hydraulic Rams 74 - 3 Boom Ram - Removal (cont’d) Remove the hoses, and install plugs or caps to prevent contamination. Remove the nut and bolt and push out the pin with a hammer and bar.
Page 485 Hydraulics Section E Section E 74 - 4 Hydraulic Rams 74 - 4 Boom Ram - Replacement (cont’d) Install the pin and then the bolt and nuts. ! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out.
Page 486 Hydraulics Section E Section E 74 - 5 Hydraulic Rams 74 - 5 Boom Ram - Replacement (cont’d) Install the collar and then the bolt and nuts. When checking or refitting JS machine pivot pins, the retaining nuts and bolts should not be fastened up tight but must have approximately 3mm of play so that the pin is free from tension.
Page 487 Hydraulics Section E Section E 75 - 1 Hydraulic Rams 75 - 1 Dismantling Details of Service Tools used in the dismantling and Assembly procedures are given in Service Tools, Section 1 . Before starting work, clean all surfaces with a suitable solvent and dry with compressed air.
Page 488 Hydraulics Section E Section E 75 - 2 Hydraulic Rams 75 - 2 Dismantling (cont’d) Remove the piston rod. Make sure that the piping ports are opened. Catch the oil coming out from the rod side (cylinder head side) port. With the piston rod extended fully, remove the cylinder head carefully.
Page 489 Hydraulics Section E Section E 75 - 3 Hydraulic Rams 75 - 3 Dismantling (cont’d) Remove the piston, cushion bearing, cushion seal, cylinder head in that order. (There is no cushion seal for the bucket ram). Remove the piston seal. The piston rings can be easily removed by hand.
Page 490 Hydraulics Section E Section E 75 - 4 Hydraulic Rams 75 - 4 Dismantling (cont’d) Dismantling the retraction side cushion (dipper ram). When there is a cushion bearing installed on the piston rod, after removing the nut A, dismantle as indicated below.
Page 491 Hydraulics Section E Section E 75 - 5 Hydraulic Rams 75 - 5 Assembly Note: See Torque Setting Figures. Clean each part in a suitable solvent and dry using compressed air. Inspect all parts and renew as required. Care must be taken not to let dust or dirt adhere to parts after cleaning and that parts do not become dented, scratched or damaged.
Page 492 Hydraulics Section E Section E 75 - 6 Hydraulic Rams 75 - 6 Assembly (cont’d) Piston Assembly. a Place the piston N on the press and using the jig P as shown, install the seal ring Q (pre-assemble the 'O'-ring R and one back up ring S beforehand). b After attaching the seal ring Q and one more back- up ring T, ensure the seal ring Q is fully seated by using jig U.
Page 493 Hydraulics Section E Section E 75 - 7 Hydraulic Rams 75 - 7 Assembly (cont’d) Retraction side cushion assembly (dipper ram) Where there is a cushion at the retraction side (end of piston rod JJ) assemble the cushion bearing as follows: a Expand the slit of the cushion seal HH and place the seal on the end of the piston rod JJ.
Page 494 Hydraulics Section E Section E 75 - 8 Hydraulic Rams 75 - 8 Assembly (cont’d) Assemble the piston rod into the cylinder. a Secure the cylinder vertically or horizontally, insert the piston into the cylinder. Note: When inserting the piston into the cylinder take care prevent the piston rings from falling off.
Page 495 Hydraulics Section E Section E 75 - 9 Hydraulic Rams 75 - 9 Assembly (cont’d) Inspection after Assembly No-load Operation Operations are smooth and there are no abnormalities with each part after full stroking more Inspection than five times with no load. Measurement Confirm the maximum extension and stroke.
Page 496 Hydraulics Section E Section E 75 - 10 Hydraulic Rams 75 - 10 Ram Piston Head Nut - Removal and Fitting JS00980 9803/6420 Issue 1...
Page 497 ) or from the auxiliary rig with the piston rod supported by block J. circuit of a JCB machine equipped with quick-release couplings. In either case, small bore hoses E (Part No. Secure the eye end of the piston rod to the rig at 892/00137 - 2 off) must be used to connect the rig to the position G, using a suitable pivot pin.
Page 498 Hydraulics Section E Section E 75 - 12 Hydraulic Rams 75 - 12 Ram Piston Head Nut (cont’d) Nut Fitting (cont’d) Required Tightening Necessary Gauge Torques Pressure lbf ft lbf/in 1400 1033 1470 1084 10.1 1790 1320 12.3 1840 1357 12.7 1900 1401...
Page 499 Hydraulics Section E Section E 76 - 1 Hydraulic Rams 76 - 1 Reconditioning Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. This section should be used in conjunction with Boom, Dipper and Bucket Rams, Dismantling and Assembly. Procedures for inserting and bedding the seal ring.
Page 500 Hydraulics Section E Section E 76 - 2 Hydraulic Rams 76 - 2 Reconditioning (cont’d) Outer guide jig fitting Mount outer guide jig E over inner guide jig B and using plate F, continue pressing the plate by hand until outer guide jig E touches seal ring D.
Page 501 Hydraulics Section E Section E 76 - 3 Hydraulic Rams 76 - 3 Reconditioning (cont’d) Bedding jig preparation Set bedding jig G underneath the press. Apply a thin coat of lubricant to the tapered section of bedding jig G and place the jig with the tapered section facing up.
Page 502 Hydraulics Section E Section E 76 - 4 Hydraulic Rams 76 - 4 Reconditioning (cont’d) Removal of bedding jig After completion of the bedding of seal ring D, remove the jig in the following order. Retract the press rod. Remove bedding jig G. This completes the fitting and bedding of the seal ring.
Page 503 Hydraulics Section E Section E 77 - 1 Hydraulic Rams 77 - 1 Reconditioning (cont’d) Bushing Removal Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. Cylinder head setting Place the cylinder head on the work bench with the cylinder tube connecting surface facing up.
Page 504 Hydraulics Section E Section E 77 - 2 Hydraulic Rams 77 - 2 Reconditioning (cont’d) Bushing Removal (cont’d) Gradually insert chuck assembly A into cylinder head B Setting the chuck assembly until its blade end reaches bushing end X. Insert chuck assembly A into the cylinder head B, taking care that parts of the blade do not damage the inner circumferential surface.
Page 505 Hydraulics Section E Section E 77 - 3 Hydraulic Rams 77 - 3 Reconditioning (cont’d) Bushing Removal (cont’d) Gently place retainer D on the stepped portion of wedge F Attaching the retainer inside the chuck assembly A. Place so that collar E is uppermost as shown. Keep the press bench clean to prevent dust, chipped metal and other foreign material causing damage to the bottom of the chuck assembly.
Page 506 Hydraulics Section E Section E 77 - 4 Hydraulic Rams 77 - 4 Reconditioning (cont’d) Bushing Removal (cont’d) Choose a block suitable in shape and size from the table Block preparation below. Position the cylinder head centrally on block G as shown.
Page 507 Hydraulics Section E Section E 77 - 5 Hydraulic Rams 77 - 5 Reconditioning (cont’d) Bushing Removal (cont’d) After removing the cylinder head assembly B from Removing chuck assembly with bushing attached under the press, remove retainer D from cylinder head B and, grasping both sides of the cylinder head B, set aside.
Page 508 Hydraulics Section E Section E 77 - 6 Hydraulic Rams 77 - 6 Reconditioning (cont’d) Bushing Removal (cont’d) With chuck assembly A and the bushing removed, turn Retightening the adjuster the adjuster with your fingers until there is no gap between the adjuster and the wedge upper surface.
Page 509 Hydraulics Section E Section E 77 - 7 Hydraulic Rams 77 - 7 Reconditioning (cont’d) Bushing Assembly Note: Jig details are in accordance with ram sizes. See Service Tools, Section 1. Cylinder head setting Set cylinder head B on the press bench with the tube connecting surface facing up.
Page 510 Hydraulics Section E Section E 77 - 8 Hydraulic Rams 77 - 8 Reconditioning (cont’d) Bushing Assembly (cont’d) Gently place retainer D so that its end is aligned with Attaching the retainer wedge stepped section Z of chuck assembly A. Place retainer D so that the larger diameter part is facing up as shown.
Page 511 Hydraulics Section E Section E 77 - 9 Hydraulic Rams 77 - 9 Reconditioning (cont’d) Bushing Assembly (cont’d) At the press, push on adjuster head J and gradually Press-fitting the bushing press-fit bushing H into the specified position in the cylinder head.
Page 512 Hydraulics Section E Section E 77 - 10 Hydraulic Rams 77 - 10 Reconditioning (cont’d) Wiper Ring Assembly Note: Keep the work bench clean so that no dust or other Setting the cylinder head foreign matter can damage the bottom surface of the cylinder head.
Page 513 Hydraulics Section E Section E 77 - 11 Hydraulic Rams 77 - 11 Reconditioning (cont’d) Wiper Ring Assembly (cont’d) Position cylinder head B and retainer D underneath the Preparation for press-fitting press. Adjust so that the shaft centre of the press and retainer D are in line as shown.
Page 514 Hydraulics Section E Section E 77 - 12 Hydraulic Rams 77 - 12 Reconditioning (cont’d) Cylinder Head Assembly Handle piston rod A with care to prevent damage to its Fixing the piston rod outer surface. Position piston rod A so that the threaded part is facing you.
Page 515 Hydraulics Section E Section E 77 - 13 Hydraulic Rams 77 - 13 Reconditioning (cont’d) Cylinder Head Assembly (cont’d) Locate cylinder head C onto piston rod A, wiper ring D Inserting the cylinder head side first, to the specified position, sliding on the peripheral surface of guide B.
Page 516 Hydraulics Section E Section E 78 - 1 Hydraulic Rams 78 - 1 Fault Finding The chart below lists some possible problems and suggested remedies. The types of problems fall into four main categories as follows: Item Symptoms Oil leakage from piston rod sliding part. Oil leakage from cylinder head joint.
Page 517 Hydraulics Section E Section E 78 - 2 Hydraulic Rams 78 - 2 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Packing rubber is perished. The packing life or hydraulic oil deterioration and high temperature are possible reasons. 1 Renew hydraulic oil. Rod packing 2.
Page 518 Hydraulics Section E Section E 78 - 3 Hydraulic Rams 78 - 3 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Foreign matter on inner • Remove foreign matter. and outer diameters. • Renew 'O'-ring if damaged. • Inspect inside tube: if any scratches or O-ring damaged.
Page 519 Hydraulics Section E Section E 78 - 4 Hydraulic Rams 78 - 4 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Poor Bending to more than the • Replace with new part. operation Piston rod specified limit. The seal and sliding part material may be cylinder tube (Bending distortion: damaged too, so inspect.
Page 520 Hydraulics Section E Section E 78 - 5 Hydraulic Rams 78 - 5 Fault Finding (cont’d) Item Symptoms Related Parts Trouble Treatment Air remaining inside ram. • Bleed the air. Operation is unsteady For rams that do not have an air bleeder, operate back and forth several times at low pressure and low speed to bleed the air.
Page 521 Hydraulics Section E Section E 79 - 1 Hydraulic Rams 79 - 1 Maintenance Specifications Piston Rod Outer Diameter Wear Limit Nominal diameter Minimum outer diameter Treatment (in) (in) 55~80 (2.17~3.15) -0.023 (-0 .001) Renew or replate 85~120 (3.35~4.73) -0.027 (-0 .001) Renew or replate Rod Bushing Inner Diameter Wear Limit...
Page 522 Hydraulics Section E Section E 79 - 2 Hydraulic Rams 79 - 2 Testing Hose Burst Check Valve - Arm Ram JS 330 Port P Port E Warm up hydraulic system to 50 °C. Raise MRV/ARV pressure to 365 bar (5294 lbf/in Set dipper to fully extend position with bucket 300 mm (12”) above ground and operate the emergency stop button, to stop the engine.
Page 523 Hydraulics Section E Section E 79 - 3 Hydraulic Rams 79 - 3 Testing Boom Hose Burst Check Valve XO330 VIEW OF LEFT HAND BOOM CYLINDER Port E Port P Warm up hydraulic system to 50 °C. Raise MRV/ARV pressure to 365 bar (5294 lbf/in Set dipper to vertical position with bucket 300 mm (12”) above ground and operate the emergency stop button to stop the engine.
Page 524 Hydraulics Section E Section E 80 - 1 *Rotary Coupling - JS450 80 - 1 Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centreline. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360°...
Page 525 Hydraulics Section E Section E 80 - 2 Rotary Coupling - JS330 and JS460 80 - 2 Operation The coupling is located in the centre of the machine between the lower and upper sections and rotates around the slew centreline. The supply and return oil flow to the coupling, piped from the upper to the lower section, is not affected by the rotational movement and allows the machine to slew 360°...
Page 526 Hydraulics Section E Section E 81 - 1 Rotary Coupling JS450 81 - 1 Removal and Replacement JS10510 JS10520 9803/6420 Issue 2*...
Page 527 Remove the three mounting bolts E and lift the rotary coupling assembly F clear of the lower frame. Installation Installation is the reverse of removal. Apply JCB Threadlocker and Sealer to screws C. Torque Settings Item lbf ft kgf m...
Page 528 Hydraulics Section E Section E 82 - 1 Rotary Coupling 82 - 1 Dismantling Remove screws 20 and cover 19. JS00140 Remove and discard 'O'-ring 18. JS00150 Remove screws 17 and thrust plate 16. JS00160 Using a jig (see Special Tools, Section 1), push off axle 11 from the rotor 13.
Page 529 Hydraulics Section E Section E 82 - 2 Rotary Coupling 82 - 2 Dismantling (cont’d) Remove and discard V-ring 12 from axle 11. Remove and discard 'O'-ring 14 and packing rings 15 from rotor 13. JS00190 9803/6420 Issue 1...
Page 530 Hydraulics Section E Section E 82 - 3 Rotary Coupling 82 - 3 Assembly Inspect the parts for signs of wear, pitting, scratching, discolouration etc. Polish out scratches using a fine grade oil stone. Before assembly, thoroughly clean all parts using a suitable solvent: Do NOT use solvents on 'O'-rings, back-up rings and seals.
Page 531 Hydraulics Section E Section E 82 - 4 Rotary Coupling 82 - 4 Assembly (cont’d) After installing the 'O'-ring and packing rings, check with a mirror to see if they are installed correctly. After checking, coat with grease then check once more for any protrusion, twisting, etc.
Page 532 Hydraulics Section E Section E 82 - 5 Rotary Coupling 82 - 5 Assembly (cont’d) Install 'O'-ring 18 into the rotor 13. Install cover 19 onto the rotor 13 using cap screws 20. Torque Settings 31.46 - 37.29 Nm (23.2 - 27.5 lbf ft) JS00200 9803/6420 Issue 1...
Page 533 Section E Section E 83 - 1 Slew Motor 83 - 1 Specifications JS330 Motor type Fixed displacement piston motor Reduction gear type Planetary gear with 2 gear reduction Slew parking brake type Mechanical lock (slew lever and slew lock switch interlocked...
Page 534 Hydraulics Section E Section E 83 - 2 Slew Motor 83 - 2 Hydraulic Motor Components Relief valve Reverse protection valve sub-assembly 101 Drive shaft 106 Spacer 111 Cylinder block 113 Spherical bush 114 Cylinder spring 116 Push rod 117 Spacer F 118 Spacer R 121 Piston 122 Shoe...
Page 535 Hydraulics Section E Section E 83 - 3 Slew Motor 83 - 3 Motor Operating Principles The following detailed description explains the operating cycle of an individual piston. High pressure hydraulic fluid P from the pump flows via input port a and control valve A into cylinder B when it is aligned with the input side A(a) of the control plate.
Page 536 Hydraulics Section E Section E 83 - 4 Slew Motor 83 - 4 Slew Brake Operation Cylinder block 111 is splined to output shaft 101. Two friction plates 742 are splined to the outer edge of the cylinder block and are interleaved between three counter plates 743 which are fixed to the slew motor casing 301.
Page 537 Hydraulics Section E Section E 92 - 1 Slew Motor 92 - 1 Dismantling Note: The part numbers quoted in the following Dismantling and Assembly procedures relate to the illustration on page 83 - 2. Plug or tape over the hydraulic ports and thoroughly I f r e n e w i n g b e a r i n g 4 4 3 , p o s i t i o n t h e d r i v e clean and dry the motor housing 301/valve housing shaft/bearing assembly on the bed of a press (as...
Page 538 Hydraulics Section E Section E 92 - 2 Slew Motor 92 - 2 Inspection Check all parts for wear and/or damage. Renew any components which do not fall within the wear parameters below, and dress any sliding surfaces with excessive roughness.
Page 539 Hydraulics Section E Section E 92 - 3 Slew Motor 92 - 3 Assembly Install brake piston 702 just in main housing 301 with Position main housing 301 on a bench with the slits B positioned as shown below. Screw in two M8 flange for valve housing 303 uppermost.
Page 540 Hydraulics Section E Section E 95 - 1 Slew Motor 95 - 1 Fault Finding Motor Does Not Rotate Symptom Cause Remedy a The pressure is low. The relief valve is not set correctly. Set to the correct value. The relief valve does not work properly. Plunger sticking.
Page 541 Hydraulics Section E Section E 95 - 2 Slew Motor 95 - 2 Fault Finding (cont’d) Motor Brake Working Poorly Symptom Cause Remedy a Low brake torque. The friction plate is worn out. Dismantle and renew worn parts. The brake piston is sticking. Dismantle and clean.
Page 542 Section E Hydraulics Section E 96 - 1 Slew Motor 96 - 1 Removal and Replacement - JS 460 Tier 2 A408560 Replacement Removal Replacement is a reversal of the removal sequence. Turn off engine. Operate the slew control joystick back and forth to vent residual pressure.
Page 543 Section E Hydraulics Section E 96 - 2 Slew Motor 96 -2 Dismantling Refer to the sectional drawing at start of this section as a guide to dismantling and assembly. Before attempting to dismantle the slew motor assembly, the inlet and outlet ports should be blanked and the outer surfaces washed down with a suitable solvent to remove all dirt and dust.
Page 544 Section E Hydraulics Section E 96 - 3 Slew Motor 96 -3 Dismantling - (continued) Remove screws with a 19 mm socket wrench and remove the motor. Note: Before removing the motor from the reduction gear, it is advisable to make an alignment mark on the mating faces to facilitate reassembly.
Page 545 Section E Hydraulics Section E 96 - 4 Slew Motor 96 -4 Dismantling - (continued) Remove snap ring 23 and remove the inner ring of needle bearing 22. Remove 'O'-ring 13. Remove balance plate 21. Remove the pins 15 from the balance plate.
Page 546 Section E Hydraulics Section E 96 - 5 Slew Motor 96 -5 Dismantling - (continued) Remove friction plate 9 and mating plate 10. Hold the end of cylinder 24 by hand and pull out the cylinder assembly from housing 25. Note: The oil seal 2 and the outer ring of taper roller bearing 3 remain in the housing.
Page 547 Section E Hydraulics Section E 96 - 6 Slew Motor 96 -6 Dismantling - (continued) Attach a puller to the inner ring of taper roller bearing 3 at two places and on the end of cylinder 24 spline, then extract bearing inner ring 1. Take out collar 53. Remove swash plate 6, piston assemblies 8 and retainer plate 7 together from cylinder 24.
Page 548 Section E Hydraulics Section E 96 - 7 Slew Motor 96 -7 Inspection Clean each part in a suitable solvent and dry using ! WARNING compressed air. Hydraulic Fluid Inspect all parts and act in accordance with the Fine jets of hydraulic fluid at high pressure can penetrate following table.
Page 549 Section E Hydraulics Section E 96 - 8 Slew Motor 96 -8 Inspection - (continued) Item Inspection and Maintenance Standards The crescent-shaped ports in the balance plate, which are in sliding contact with the end face of the cylinder assembly shaft, act to switch between high and low oil pressure.
Page 550 Section E Hydraulics Section E 96 - 9 96 - 9 Slew Motor Assembly ! CAUTION Refer to the sectional drawing at start of this section as a guide to dismantling and assembly. Cleaning Cleaning metal parts with incorrect solvents can cause Check all parts before assembly and remove any scratches corrosion.
Page 551 6. Mount collar 53 and inner ring of taper roller bearing 1 on motor output shaft. Apply a thin coat of JCB Retainer where the inner ring is mounted on motor output shaft. JS05720 Using a jig, (see Special Tools, Section 1) press inner ring 1 on output shaft.
Page 552 Section E Hydraulics Section E 96 - 11 96 - 11 Slew Motor Assembly - (continued) Mount the outer ring of the taper roller bearing into housing 25. 11 Hold the end of cylinder 24 by hand and carefully insert the cylinder assembly into housing 25.
Page 553 Apply grease to the 'O'-ring and install 'O'-ring 13 to cover 17. JS05680 To prevent oil leakage from the cover bolt holes apply JCB Multi-gasket to the surface. JS05650 Lift cover 17 and balance plate 21 by hand and mount them carefully on housing 25.
Page 554 Section E Hydraulics Section E 96 - 13 96 - 13 Slew Motor Assembly - (continued) Assembling the Make-up and by-pass valves. Assemble the check valves 29 and springs 31 in cover 17 and tighten the caps 30 (14 mm A/F hexagonal sockets) to a torque of 137 Nm (101 lbf ft).
Page 555 Section E Hydraulics Section E 96 - 14 96 - 14 Slew Motor Assembly - (continued) Attach the motor with hexagonal bolts and spring washers. Size: 19 mm Tightening torque: 103 Nm (76 lbf ft). JS06120 Attach the level gauge A with a pipe wrench, setting the height as shown.
Page 556 Section E Hydraulics Section E 96 - 15 Slew Motor 96 - 15 Relief Valves Dismantling Refer to the sectional drawing on page E/83-1 as a guide to dismantling and assembling. Take steps during dismantling to ensure that all the parts are returned to their original positions.
Page 557 Section E Hydraulics Section E 96 - 16 Slew Motor 96 - 16 Relief Valves Assembly Press fit seat 44 into sleeve 39 which has an 'O'-ring Mount poppet 43, spring 42, shim 40, piston 38, liner 51 onto sleeve 39. Screw cap 37 (with a 14 mm A/F hexagonal socket) with 'O'-ring 36 and back-up 35 mounted, on to sleeve 39 and tighten to a torque of 157 Nm (116 lbf ft).
Page 558 Section E Hydraulics Section E 96 - 17 Slew Motor 96 - 17 Slew Reduction Gear Assembly Component Identification Bearing 1 st Reduction Sun Gear Nylon ring Spacer 1 st Reduction Planet gear assembly Pinion shaft Cover 2 nd Reduction Sun Gear O-ring seal Ring gear O-ring seal...
Page 559 Section E Hydraulics Section E 96 - 18 Slew Motor 96 - 18 Slew Reduction Gear Dismantling Cleanliness is the utmost importantance when servicing the gearbox. All precautions to prevent any ingress of dirt, grit etc must be taken Note: For details of service tools refered to, see Service tools at the front of this section Remove bolts 3 which hold the cover 4 to the ring gear abd gear box cover 13.
Page 560 Section E Hydraulics Section E 96 - 19 Slew Motor 96 - 19 Slew Reduction Gear Dismantling - (continued) Use a 3 leg puller to release gear box housing 13 from Pinion shaft 17 and bearing. Using suitable lifting equipment , remove gearbox housing 13. A406420 Assemble the Bearing Rig (see Service Tools, Section 1) between the pinion shaft 17 and the bearing 4.
Page 561 Section E Hydraulics Section E 96 - 20 Slew Motor 96 - 20 Inspection Slew Reduction Gear Before assembling the gear box make sure that a thorough inpection of all the components is carried out. Remember that although a failed component may be easy to identify, the cause may be less easy to trace.
Page 562 10. Insert bearing 11 onto the pinion shaft 17 and using the Stopper Tool (see Service Tools, Section 1) and a press, assemble the output unit. 11. Apply JCB Threadlocker to the thread of a NEW ring nut 10. Assemble the Socket Box Wrench and Nut Adapter (see Services Tools, Section 1) on the ring nut 10.
Page 563 Section E Hydraulics Section E 96 - 22 Slew Motor 96 - 22 Slew Reduction Gear Assembly - (continued) Place 2 nd Reduction planetary gear assembly 9 over the pinion shaft 17. Replace O-ring 8 into it’s seat in the ring gear 7. Place ring gear 8 onto the gear box housing 7, making sure bolt holes are aligned.
Page 565 Removal and Replacement 6 - 1 Motor Bleeding 6 - 5 Traction Motor - JS330 7 - 1 Exploded View (Motor) - JS330 7 - 2 Components List (Motor) - JS330 7 - 3 Exploded View (Gearbox) - JS330 7 - 4...
Page 566 Braking torque (stationary) 472 Nm (640 lbf ft, 48.1kgf m) Release pressure 14 bar (199 lbf/in , 14 kgf/cm 16.7 bar (242 lbf/in , 17 kgf/cm Overall weight 360 kg (792 lbs) 726 kg (1600 lbs) Schematic (JS330, JS450) 9803/6420 Issue 1...
Page 567 Transmission Section F Section F 3 - 1 Traction Motor/Reduction Gear 3 - 1 Traction Motor The motor is of the variable swash plate, axial piston type. Pressurised oil is routed via rear flange 101 and timing plate 106 into cylinder block 104. The fixed timing plate directs oil to force piston 105 against swash plate 103, until it reaches the end of its power stroke, causing the cylinder block to rotate 180°.
Page 568 Transmission Section F Section F 3 - 2 Traction Motor/Reduction Gear 3 - 2 Brake Valve Brake Function When control valve A is returned to neutral, the pressurised oil from the pump is blocked, and pressure at P1 and P2 becomes equal, and the plunger tries to return to neutral position by the spring.
Page 569 Transmission Section F Section F 3 - 3 Traction Motor/Reduction Gear 3 - 3 Brake Valve (continued) Counterbalance Valve Motor Not Rotating Motor Rotating 9803/6420 Issue 1...
Page 570 Transmission Section F Section F 3 - 4 Traction Motor/Reduction Gear 3 - 4 Brake Valve (continued) Counterbalance Valve (continued) Refer to the top illustration. The counterbalance valve serves to prevent the stoppage of the axial piston motor and its overrun.
Page 571 Transmission Section F Section F 3 - 5 Traction Motor/Reduction Gear 3 - 5 Brake Valve (continued) The counterbalance valve has a shuttle function. When the plunger moves from the state in the top illustration to that in the lower illustration, the parking brake release port P3 is opened to guide the pressurised oil to the brake releasing cylinder.
Page 572 Transmission Section F Section F 3 - 6 Traction Motor/Reduction Gear 3 - 6 Parking Brake The parking brake consists of alternate friction and counter plates (A and B), a piston C and an activating spring D. As described under Shuttle Function, Brake Valve, pressurised oil is guided to the parking brake release cylinder via port P3.
Page 573 Transmission Section F Section F 3 - 7 Traction Motor/Reduction Gear 3 - 7 Travel Motor Speed Range Changing 9803/6420 Issue 1...
Page 574 Transmission Section F Section F 3 - 8 Traction Motor/Reduction Gear 3 - 8 Travel Motor (continued) Speed Range Changing (continued) 9803/6420 Issue 1...
Page 575 Transmission Section F Section F 3 - 9 Traction Motor/Reduction Gear 3 - 9 Travel Motor (continued) Speed Range Changing (continued) 9803/6420 Issue 1...
Page 576 Transmission Section F Section F 3 - 10 Traction Motor/Reduction Gear 3 - 10 Travel Motor (continued) Working Principles a Refer to View Y (page 3 - 8) When 2-speed control valve A is as illustrated, the motor load pressure P acts on 2-speed control piston E to tilt swash plate G until its surface K comes into contact with the motor case, thereby, selecting the high speed range.
Page 577 Transmission Section F Section F 4 - 1 Traction Motor/Reduction Gearbox 4 - 1 Preparation for Use Before installing the motor unit, ensure there are no loose parts and that nuts, screws etc. have been tightened to the correct torque values. All ports should be plugged and sealed to prevent the ingress of dirt.
Page 578 Transmission Section F Section F 5 - 1 Traction Motor/Reduction Gear 5 - 1 Fault Finding Traction Motor Symptom Possible Cause Remedy Motor does not run. Device external to the piston motor or Check that the specified pressurised reduction gear malfunctioning. oil is delivered to the motor input side.
Page 579 Transmission Section F Section F 5 - 2 Traction Motor/Reduction Gear 5 - 2 Fault Finding (continued) Parking Brake Symptom Possible Cause Remedy Braking force is low or Friction plates worn. Renew discs. Completely remove insufficient. foreign matter and repair damaged areas.
Page 580 Transmission Section F Section F 5 - 3 Traction Motor/Reduction Gear 5 - 3 Fault Finding (continued) Relief Valve Symptom Possible Cause Remedy Motor does not run or Relief valve not closing fully: rotation speed is slow. Foreign matter clogging components. Completely remove foreign matter, repair damaged part and reassemble after cleaning.
Page 581 Transmission Section F Section F 5 - 4 Traction Motor/Reduction Gear 5 - 4 Fault Finding (continued) Counterbalance Valve Symptom Possible Cause Remedy Motor does not run or Plunger not switching. rotation speed is slow. External pilot pressure not present. Inspect the piping for damage.
Page 582 Transmission Section F Section F 5 - 5 Traction Motor/Reduction Gear 5 - 5 Fault Finding (continued) Speed Range Changing Symptom Possible Cause Remedy Travel is not linear. Plunger not switching. Foreign matter between plunger and Completely remove foreign matter, body.
Page 583 Transmission Section F Section F 5 - 6 Traction Motor/Reduction Gear 5 - 6 Fault Finding (continued) Speed Range Changing (continued) Symptom Possible Cause Remedy Will not go into low speed. Spring is not installed. Install spring. Spring is broken. Renew spring.
Page 584 Transmission Section F Section F 6 - 1 Traction Motor/Reduction Gear 6 - 1 Removal and Replacement Removal Move the track link until the master pin is over the take-up roller in the position shown, place a wooden block under the track shoe as shown. JS02770 Slacken the check valve to bleed out the grease.
Page 585 Transmission Section F Section F 6 - 2 Traction Motor/Reduction Gear 6 - 2 Removal and Replacement (cont’d) Removal (cont’d) Operate the traction motor to remove the track. Lift the side of the undercarriage high enough to permit drive sprocket removal. Support with wooden blocks.
Page 586 A with the specified hydraulic oil. Fit plugs to ports A and B. Lift the assembly and position it on the undercarriage. Install the bolts and washers, using JCB Threadlocker and Sealer on the bolt threads. Tighten the bolts in a diagonal sequence.
Page 587 Transmission Section F Section F 6 - 4 Traction Motor/Reduction Gear 6 - 4 Removal and Replacement (cont’d) Replacement (cont’d) a Install the covers over the motor. b Check the amount of oil in the gearbox. c Bleed air from the motor (see Motor Bleeding). d If the traction motor has been dismantled and serviced, carry out the functional tests detailed under Testing later in this section.
Page 588 Transmission Section F Section F 6 - 5 Traction Motor/Reduction Gear 6 - 5 Removal and Replacement (cont’d) Replacement (cont’d) Apply grease through the check valve to adjust the track tension (see Tracks and Running Gear, Checking/Adjusting the Track Tension, Section 3). Motor Bleeding Bleeding must be done whenever a track motor is being fitted.
Page 589 Transmission Section F Section F 7 - 1 Traction Motor/Reduction Gear 7 - 1 Traction Motor - JS330 JS09980 9803/6420 Issue 1...
Page 590 Transmission Section F Section F 7 - 2 Traction Motor/Reduction Gear 7 - 2 Traction Motor - JS330 9803/6420 Issue 1...
Page 591 Transmission Section F Section F 7 - 3 Traction Motor/Reduction Gear 7 - 3 Traction Motor - JS330 Component List Item Description Qty. Item Description Qty. Case 2 - 24 Plug Base plate assembly Shaft 2 - 1 Base plate...
Page 592 Transmission Section F Section F 7 - 4 Traction Motor/Reduction Gear 7 - 4 Reduction Gear - JS330 9803/6420 Issue 1...
Page 593 Transmission Section F Section F 7 - 5 Traction Motor/Reduction Gear 7 - 5 Reduction Gear - JS330 Component List Item Description Qty. Holder A assembly Holder assembly Planetary gear A Needle bearing Inner race Thrust washer Screw Thrust plate...
Page 594 Transmission Section F Section F 7 - 6 Traction Motor/Reduction Gear 7 - 6 Traction Motor - JS450 9803/6420 Issue 1...
Page 596 Transmission Section F Section F 7 - 7 Traction Motor/Reduction Gear 7 - 7 Traction Motor - JS450 9803/6420 Issue 1...
Page 597 Transmission Section F Section F 7 - 8 Traction Motor/Reduction Gear 7 - 8 Traction Motor - JS450 Component List Item Description Qty. Item Description Qty. Case Spring Rear cover assembly 2 - 1 Rear cover Washer 2 - 2 Valve assembly Snap ring Valve body...
Page 598 Transmission Section F Section F 7 - 9 Traction Motor/Reduction Gear 7 - 9 Traction Motor - JS460 11-1 11-2 31-16 31-17 31-10 31-15 31-12 31-14 31-6 31-13 31-11 31-6 31-8 31-9 31-4 31-7 31-2 31-5 31-1 31-2 31-3 374760 9803/6420 Issue 1...
Page 599 Transmission Section F Section F 7 - 10 Traction Motor/Reduction Gear 7 - 10 Traction Motor - JS460 Component List Item Description Qty. Housing Screw Not used Carrier 4 - 1 Gear 4 - 2 Circlip Washer Gear Carrier 7 - 1 Gear 7 - 2 Circlip...
Page 600 Refer to the following pages: Make different alignment marks across sub assembly joint faces as an aid to assembly. JS330 7 - 1 and 7 - 2 (illustrations) 7 - 3 (component list) The cylinder block assemblies, servo pump, relief valve and proportional pressure reduction valve must be renewed as complete assemblies.
Page 601 Transmission Section F Section F 8 - 2 Traction Motor 8 - 2 Dismantling (continued) Counterbalance valve disassemble Loosen socket head bolt 2-6-5 and remove cap 2-6 . Note: Since the cap is loaded by a spring, loosen the socket head bolt halfway and while pressing the cap by hand, remove the socket head bolt.
Page 602 Transmission Section F Section F 8 - 3 Traction Motor 8 - 3 Dismantling (continued) Base plate disassembly a Loosen socket head bolt 20. Note: Since the base plate is forced upwards by springs, loosen the bolts evenly. Remove the socket head bolts 20 and using a screwdriver, etc.
Page 603 Transmission Section F Section F 8 - 4 Traction Motor 8 - 4 Dismantling (continued) Brake piston disassembly a Through case orifice apply compressed remove brake piston 25 from the case and also remove disk 26 and friction plate 27. Note: Because the brake piston may fly out due to the compressed air, take sufficient care to do the work safely.
Page 604 Transmission Section F Section F 8 - 5 Traction Motor 8 - 5 Dismantling (continued) Remove piston 6, retainer plate 7, retainer holder 8 and pin 19 from cylinder block 4. Remove snap ring 14 using a jig or press and remove spring seat 15, spring 16 and spring seat 17.
Page 605 Transmission Section F Section F 8 - 6 Traction Motor 8 - 6 Dismantling (continued) Remove shaft 3 from case 1 and remove swash plate 9, piston 11, spring 40 and steel ball 10 from case 1. Plunger disassembly ø ø...
Page 606 Transmission Section F Section F 8 - 7 Traction Motor 8 - 7 Inspection All parts should be inspected for signs of wear or damage, paying particular attention to those detailed below. Parts should be handled carefully to avoid damage, with particular attention being paid to the moving and sliding surfaces.
Page 607 Transmission Section F Section F 8 - 8 Traction Motor 8 - 8 Inspection (continued) Description Appearance Standard Value Wear Limit Remedy Shaft 3 1 Sliding area of oil seal 21 is 0.8a 1.6a Fit new shaft. deeply scarred or rough. 2 Excessively worn or broken teeth.
Page 608 Transmission Section F Section F 8 - 9 Traction Motor 8 - 9 Assembly Assembly is essentially a reverse of the dismantling procedure in the previous section. Exchange or repair any parts not in accordance with instructions laid down in the Maintenance Standards. Ensure that all parts are cleaned in the appropriate solvent and dried with compressed air.
Page 609 Transmission Section F Section F 8 - 10 Traction Motor 8 - 10 Assembly (continued) Assemble piston 6 into retainer plate 7 and insert into cylinder block 4. Note: Assemble them so that the small diameter of the inner taper of the retainer plate comes into contact with the flange of the piston shoe.
Page 610 Transmission Section F Section F 8 - 11 Traction Motor 8 - 11 Assembly (continued) Assemble oil seal 21 to case 1. Assemble ball bearings 12 into case 1. 9803/6420 Issue 1...
Page 611 Transmission Section F Section F 8 - 12 Traction Motor 8 - 12 Assembly (continued) Assemble the steel balls 10, spring 40 and piston 11 into case 1. Install shaft 3 into case 1. Note: Be careful not to damage the oil seal lip. 9803/6420 Issue 1...
Page 612 Transmission Section F Section F 8 - 13 Traction Motor 8 - 13 Assembly (continued) Assemble swash plate 9 to case 1. Place case 1 on the work bench horizontally and insert cylinder block 4 into the case. Next, assemble disk 26 and friction plate 27 in order.
Page 613 Transmission Section F Section F 8 - 14 Traction Motor 8 - 14 Assembly (continued) Assemble D rings 30 and 31 which have been greased into brake piston 25. Assemble brake piston 25 into case 1. Align so that the two pinholes of brake piston 25 and the two pinholes of case 1 are aligned.
Page 614 Transmission Section F Section F 8 - 15 Traction Motor 8 - 15 Assembly (continued) Fix case 1 in a vice and assemble base plate 2-1 to the case and secure with socket head bolts 20 tightened to a torque of 108 ± 10 Nm (11 ± 1.0 kgf m, 79.5 ± 7.2 lbf ft).
Page 615 Transmission Section F Section F 8 - 16 Traction Motor 8 - 16 Assembly (continued) Assemble spring 2-3 and spring seat 2-5 in order. Assemble cap 2-6-1 to base plate 2-1 and fasten with socket head bolts 2-6-5. Note: Because it is pushed upwards by the spring, press down by hand and tighten the socket head bolts to the specified tightening torque, i.e.
Page 616 Transmission Section F Section F 9 - 1 Reduction Gear - JS330 9 - 1 Dismantling Refer to the following pages: 7 - 4 (illustration) 7 - 5 (component list) In the following procedures, the part numbers in bold type (e.g.
Page 617 Transmission Section F Section F 9 - 2 Reduction Gear - JS330 9 - 2 Dismantling (continued) Remove thrust plate 23, drive gear 4 and holder A sub- assembly 1. Remove the sun gear B 6, holder B sub-assembly 2.
Page 618 Transmission Section F Section F 9 - 3 Reduction Gear - JS330 9 - 3 Dismantling (continued) Loosen the socket head bolts 21 and remove ring gear Remove sun gear C 8. 9803/6420 Issue 1...
Page 619 Transmission Section F Section F 9 - 4 Reduction Gear - JS330 9 - 4 Dismantling (continued) Loosen the socket head bolts 17 and 16 and remove holder C sub-assembly 3. Dismantle the holder sub-assemblies by knocking the relevant spring pins into the gear shaft, as follows:...
Page 620 Transmission Section F Section F 9 - 5 Reduction Gear - JS330 9 - 5 Dismantling (continued) Remove floating seal 11 and angular bearing 12. 9803/6420 Issue 1...
Page 621 Transmission Section F Section F 9 - 6 Reduction Gear - JS330 9 - 6 Inspection All parts should be inspected for signs of wear or damage, paying particular attention to those detailed below. Parts should be handled carefully to avoid damage with particular attention being paid to gear teeth and bearing rotation surfaces.
Page 622 Transmission Section F Section F 9 - 7 Reduction Gear - JS330 9 - 7 Inspection (continued) Description Appearance Standard Value Wear Limit Remedy Thrust plate 23 1 Worn Renew thrust plate 23 Note: The figures right are for alternative thrust plates. Be sure to check against correct standard value.
Page 623 Transmission Section F Section F 9 - 8 Reduction Gear - JS330 9 - 8 Assembly General Clean each part in a suitable solvent and dry using All tapped holes and gasket faces should be thoroughly compressed air. degreased by washing, as liquid packing and adhesive is used on all gasket surfaces and threads.
Page 624 Transmission Section F Section F 9 - 9 Reduction Gear - JS330 9 - 9 Assembly (continued) Lower housing 13 onto flange 10. Assemble the other inner ring sub-assembly of angular bearing 12 to flange 10. Press fit pin 15 into flange 10 so that the pin protrudes 21.5 - 22.
Page 625 Align the pin hole of holder C 3-1 with pin 15 and fit to flange 10. Secure with socket head bolts 16, treated with JCB Threadlocker and Sealer (High Strength) tightened to a torque of 417 ± 25 Nm (307 ± 18 lbf ft, 42.5 ±...
Page 626 Transmission Section F Section F 9 - 11 Reduction Gear - JS330 9 - 11 Assembly (continued) Assemble holder A sub-assembly 1 as follows: a Install needle bearing 1-3 in planetary gear 1-2 with a thrust washer 1-5 on each side.
Page 627 Transmission Section F Section F 9 - 12 Reduction Gear - JS330 9 - 12 Assembly (continued) Assemble holder B sub-assembly 2 as follows: a Coat grease on the inside of the planetary gears 2-2. Place a thrust washer 2-5 on the lower side only.
Page 628 Transmission Section F Section F 9 - 13 Reduction Gear - JS330 9 - 13 Assembly (continued) Assemble holder C sub-assembly 3 as follows: a Coat grease on the inside of the planetary gears 3-2. Place a thrust washer 3-7 on the lower side only of each planetary gear and insert floating bushings 3-5.
Page 629 Section F Section F 9 - 14 9 - 14 Reduction Gear - JS330 Assembly (continued) 11 Install three pins 22 into housing 13 so that they protrude 22.0 - 22.5 mm from the housing. Smear grease on O-ring 20 and install on housing 13.
Page 630 Transmission Section F Section F 9 - 15 Reduction Gear - JS330 9 - 15 Assembly (continued) Lower ring gear 19 onto housing 13 and secure with socket head bolts 21 tightened to a torque of 191 ± 15 Nm (141 ±...
Page 631 Transmission Section F Section F 9 - 16 Reduction Gear - JS330 9 - 16 Assembly (continued) 16 Smear grease on thrust plate 5 and fit to holder A, sub- assembly 1. Install holder A sub-assembly 1. Install drive gear 4.
Page 632 Assembly (continued) 19 Fit thrust plate 23. 20 Coat the mating surface of cover 24 with JCB Multi- Gasket and install on ring gear 19. Secure with socket head bolts 25 tightened to a torque of 58.8 ± 4.9 Nm (43.4 ±...
Page 633 27 12.3 ± 2.5 Nm (9 ± 1.8 lbf, 1.25 ± 0.25 kgf m). 22 Turn over the reduction gear and install plate 18. Secure with socket head bolts 17, coated with JCB Threadlocker and Sealer, tightened to a torque of 417 ± 25 Nm (307 ±...
Page 634 Transmission Section F Section F 9 - 19 Reduction Gear - JS330 9 - 19 Assembly (continued) 24 Fill with lubricant (see Fluids and Lubricants, Section 9803/6420 Issue 1...
Page 635 Track and Running Gear Section J Section J Contents Page No. Torque Specifications 1 - 1 Idler Wheel and Recoil Unit Removal 2 - 1 Replacement 2 - 2 Idler Wheel Dismantling 3 - 1 Assembly 3 - 2 Wear Limits 4 - 1 Recoil Unit Dismantling...
Page 636 663 - 775 Shoe Bolts (STD) 775 - 931 77 - 95 557 - 687 (HD) 980 - 1180 100 - 120 723 - 871 Note: Apply JCB Threadlocker and Sealer to the threads of the above bolts. 9803/6420 Issue 1...
Page 637 Track and Running Gear Section J Section J 2 - 1 Idler Wheel and Recoil Unit 2 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 638 Track and Running Gear Section J Section J 2 - 2 Idler Wheel and Recoil Unit 2 - 2 Replacement Before fitting the idler wheel, check the oil level at A. If required, top up with the specified oil (see section 3). Assemble the idler wheel to the recoil unit and fit the mounting bolts.
Page 639 Track and Running Gear Section J Section J 3 - 1 Idler Wheel 3 - 1 Dismantling Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal. Clean the idler wheel with a suitable solvent. Remove the plug A from hub B and drain the oil. On one side of the unit only, remove the wire clip E or roll pin F and separate the hub C from shaft D.
Page 640 Track and Running Gear Section J Section J 3 - 2 Idler Wheel 3 - 2 Dismantling (cont’d) Remove floating seal J from each hub C using a pry bar. Remove floating seal J from each side of idler wheel G using a pry bar.
Page 641 Track and Running Gear Section J Section J 3 - 3 Idler Wheel 3 - 3 Assembly (cont’d) Apply a coating of grease and install a new floating seal J into each side of the idler wheel G. Apply a coating of grease and install a new floating seal J into hub C.
Page 642 Track and Running Gear Section J Section J 3 - 4 Idler Wheel 3 - 4 Assembly (cont’d) Apply grease to a new 'O'-ring I and install it on the shaft Clean the metallic face of the seal, coat the metallic face with engine oil and install the hub C onto the shaft D.
Page 643 4 - 1 Idler Wheel 4 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Wheel Diameter JS330 23.62 23.22 Build up or renew JS450 26.22 25.79 Build up or renew JS330 0.79 Build up or renew JS450 0.98...
Page 644 Track and Running Gear Section J Section J 5 - 1 Recoil Unit 5 - 1 Dismantling Carry out steps 1 to 4 of Idler Wheel and Recoil Unit, Removal. ! WARNING RECOIL UNITS ARE DANGEROUS. They must not be dismantled without using suitable tools to compress the spring safely.
Page 645 Track and Running Gear Section J Section J 5 - 2 Recoil Unit 5 - 2 Assembly a Position the recoil unit component parts in the spring compression jig (see Service Tools, Section 1), starting with spring guide/retainer F, then spring B and yoke E.
Page 646 E and use a press (as shown) to fully retract the cylinder and expel the grease. Refit the check valve. JS01530 Apply JCB Threadlocker and Sealer to the threads of mounting bolts A. When installing the grease cylinder, make sure it is orientated so that check valve E is facing outwards to the side of the machine.
Page 647 Track and Running Gear Section J Section J 7 - 1 Drive Sprocket 7 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 648 Replacement Support the sprocket and position it on the gearbox. Install the bolts and washers, using JCB Threadlocker and Sealer on the bolt threads. Tighten the bolts in a diagonal sequence to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).
Page 649 Track and Running Gear Section J Section J 8 - 1 Drive Sprocket 8 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Width JS330 3.15 2.76 Renew JS450 4.02 3.54 Renew Diameter JS330 27.01 26.69 Renew JS450 30.31...
Page 650 Track and Running Gear Section J Section J 9 - 1 Top Roller 9 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve, always stand to one side and loosen a little at a time until grease starts to come out.
Page 651 3). Install the plug using an appropriate pipe thread sealant. With the track supported as shown under Removal, step 2, install the roller. Apply JCB Threadlocker and Sealer to the threads and fit the mounting bolts. Remove the wooden blocks and jack.
Page 652 Track and Running Gear Section J Section J 10 - 1 Top Roller 10 - 1 Dismantling Item Part Name Roller Plug Circlip Cover ‘O’-ring Bolt Thrust plate Shaft Floating seal Bush Bush Mounting bracket JS01540 9803/6420 Issue 1...
Page 653 Track and Running Gear Section J Section J 10 - 2 Top Roller 10 - 2 Dismantling (cont’d) Clean the upper roller A with an appropriate detergent. Remove the plug B from the cover and drain the oil. Remove the circlip C, and remove cover D. From cover D, remove 'O'-ring E and discard.
Page 654 Track and Running Gear Section J Section J 10 - 3 Top Roller 10 - 3 Dismantling (cont’d) Remove the floating seal I from the upper roller A. If badly worn or damaged, remove the bushes J and K, from the roller A. Remove floating seal I from bracket L using a pry bar.
Page 655 Track and Running Gear Section J Section J 10 - 4 Top Roller 10 - 4 Assembly (cont’d) Using a jig M, and hammer, insert the bushes J and K into the roller A. JS01550 Install a new floating seal I into the roller A. Coat the metallic face of the seal with engine oil.
Page 656 Track and Running Gear Section J Section J 10 - 5 Top Roller 10 - 5 Assembly (cont’d) Apply grease to the inside face of thrust plate G and install it on the shaft using bolts F. JS01560 Apply grease to a new 'O'-ring E and install it onto cover D.
Page 657 Track and Running Gear Section J Section J 10 - 6 Top Roller 10 - 6 Wear Limits Item Dimension Machine Standard Size Service Limit Action Carrier roller JS330 5.71 5.39 Renew JS450 6.30 5.90 Renew JS330 0.39 Renew JS450 0.59 Renew JS330 3.94...
Page 659 Track and Running Gear Section J Section J 11 - 1 Top Roller - JS450/460 11 - 1 Item Part Name Track roller unit Bracket Spring pin Duo -cone seal ‘O’-ring Shaft Roller body Screw plug Bushing 9803/6420 Issue 1*...
Page 660 Track and Running Gear Section J Section J 12 - 1 Bottom Roller 12 - 1 Removal Slacken the check valve to bleed out grease. ! WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out.
Page 661 Lower the undercarriage sufficient to allow the mounting bolts to be installed. Apply JCB Threadlocker and Sealer to the threads and install the mounting bolts. Tighten to a torque of 267 - 312 Nm (197 - 230 lbf ft, 27 - 31 kgf m).
Page 662 Track and Running Gear Section J Section J 13 - 1 Bottom Roller 13 - 1 Dismantling Item Part Name Plug Locking wires Shaft Mounting bracket Mounting bracket Floating seal ‘O’-ring Roller (outer flange) Roller (inner flange) Bushing JS01590 9803/6420 Issue 1...
Page 663 Track and Running Gear Section J Section J 13 - 2 Bottom Roller 13 - 2 Dismantling (cont’d) Clean the roller with a suitable solvent. Remove the plug A and drain the oil. Remove locking wire B from each end of shaft C. Remove mounting brackets D and E from shaft C.
Page 664 Track and Running Gear Section J Section J 13 - 3 Bottom Roller 13 - 3 Dismantling (cont’d) Remove floating seals F from roller H or J using a pry bar. If badly worn or damaged, remove and discard bushes K from roller H or J, using a press or puller.
Page 665 Track and Running Gear Section J Section J 13 - 4 Bottom Roller 13 - 4 Assembly (cont’d) Coat shaft C with grease. Insert the shaft into roller H or J. Apply grease to new 'O'-rings G and install them on shaft C.
Page 666 Track and Running Gear Section J Section J 13 - 5 Bottom Roller 13 - 5 Assembly (cont’d) Complete the installation of locking wires B by tapping with a hammer Fill the unit with oil (see Fluids and Lubricants, Section 3) and install plug A using an appropriate pipe thread sealant.
Page 667 Track and Running Gear Section J Section J 14 - 1 Bottom Roller 14 - 1 Wear Limits Item Dimension Machine Standard Size Service Limit Action Roller diameter JS330 7.09 6.77 Renew JS450 8.27 7.79 Renew JS330 0.79 Renew JS450 0.98 0.79...
Page 668 Track and Running Gear Section J Section J 15 - 1 Bottom Roller - JS460 15 - 1 Item Part Name Support roller unit Roller body complete Shaft complete Duo -cone seal Endplate Cover Screw Spring washer O-ring Thrust washer Roller body Bushing Bushing...
Page 669 Engine Section K Section K Contents Page No. Routine Maintenance See Section 3 Technical Data 1 - 1 9803/6420 Issue 1...
Page 670 Air Cleaner Type 2 stage, dry element For further details, see JS330 Engine Service Manual, Publication No. 9806/2160 For further details, see JS330 Tier 2 Engine Service Manual, Publication No. 9806/2200 Technical Data JS 450/JS460 Type Isuzu 6RB1, 6 cylinder turbo charged...
Page 671 Section K Engine Section K 1 - 2 1 - 2 Technical Data JS 460 Tier 2 Type Isuzu AA 6SD1T, 6 cylinder turbo charged Model - JS460 AA 6SD1TQB-01 Bore 120 mm (4.72 in) Stroke 145 mm (5.7 in) Swept volume 9839 cm (600 in...

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Js450 Js460