JCB JS330, JS450, JS460/500 Hydraulic Excavator Service Manual
675 pages · Publication 9803-6420
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What's inside
From the manual's own table of contents: 1 sections, 272 entries. See sample pages (PDF, 409 KB)
General162 topics
- Bolt and Nut Torque Specifications
- Torque Settings
- Section B - Body & Framework
- Section C - Electrics
- Section E - Hydraulics
- Sealing and Retaining Compounds
- Safety Notices
- General Safety
- Operating Safety
- Maintenance Safety
- Fluids and Lubricants
- Lubricants - Health and Safety
- when using a Breaker or Crusher
- Initial Precautions For New Machine Usage
- Operating Hours Schedule
- Slew Ring Bearing
- Slew Ring Teeth and Slew Pinion
- Excavator End
- Battery
- Releasing tank pressure
- Air bleeding procedures
- Air bleeding from hydraulic pump
- Air bleeding from ram
- Checking the fluid level
- Topping up fluid level
- Changing the hydraulic oil
- Changing the Return Filter Element
- Cleaning/Changing the Suction Strainer
- Changing the Air Breather Element
- Draining Tank Impurities
- Changing the Pilot Oil Filter
- Changing the Breaker In-line Filter
- Changing the Drain Line Filter
- Changing the Nephron Filter(JS450)
- Checking Track Gearbox Oil Level
- Changing the Track Gearbox Oil
- Checking the Slew Gearbox Oil Level
- Changing the Slew Gearbox Oil
- Cleaning the Tracks
- Checking/Adjusting the Track Tension
- Checking the Shoe Plate
- Checking the Rollers and Idler Wheels for Oil Leaks
- Changing the Air Filter Outer Element
- Changing the Air Filter Inner Element
- Checking the Oil Level
- Changing the Oil and Filter(s)
- Checking the Coolant Level
- Coolant Mixtures
- Changing the Coolant
- Adjusting the Fan Belt
- Fitting a New Fan Belt
- Cleaning the Radiator and Oil Cooler
- Draining Fuel Tank Impurities
- Draining the Water Separator
- Changing the Fuel Filter Element
- Bleeding the Fuel System
- Component Location Diagrams
- Performance Evaluation
- Checking the FOPS Structure
- Direct Glazing
- JS 330 Dimensions
- JS 450 Dimensions
- JS 460 Dimensions
- Boom and Slew Frame Installation
- Boom Ram Installation
- Dipper Ram Installation
- Dipper Pivot Installation
- Dipper and Dipper Ram Installation
- Bucket Ram Installation
- Dipper and Dipper link Installation
- Bucket and Bucket link Installation
- Bucket Link and Bucket Ram Installation
- Bucket and Dipper Installation
- Shim Adjustment Table
- Operation
- Control
- Safety Procedures
- Fault Finding
- Checking Refrigerant charge Level
- Leak Testing
- Tightening Leaking Hoses
- System Diagnosis
- The A.M.S. System
- Technical Data
- Battery/Battery Testing
- Schematic Diagram - JS330
- Schematic Diagram - JS450
- Schematic Diagram - JS330/JS460
- Schematic Diagram - JS460 Tier 2
- Right Console
- Left Console
- Monitor
- Summary of Engine Functions
- Stepping Motor
- Throttle Related Function
- Stop Motor Function
- Emergency Stop Button
- Redundancy (back-up) Throttle Control
- Automatic Engine Speed Adjustment
- Idling Control
- Revolution Control for each Mode
- Control of Engine Speed for Breaker Operation
- Engine Auto Warm-up
- Detection of Throttle Motor Assy Defect
- Engine Reverse Rotation Prevention
- Summary of Hydraulic System Functions
- Schematic
- Performance Data
- Flow Chart
- Boom Lowering Speed Regulation
- Cushioned Boom Starting
- Pressure Increasing System
- Speed Travel and Max Flow Cut
- Soft/Hard Switch
- Power Supply Cut Delay
- Swing Brake/Swing Lock
- Lever Lock
- Travel Warning
- Overload Protection
- Display Monitor
- High Dump
- Throttle Motor and Throttle Link Replacement
- Automatic Adjustment
- Installation
- Self Test (CAPS II)
- Section C
- Fault Diagnosis
- Emergency Engine Stop
- Refuel
- Coolant Refill
- Air Cleaner Clogged
- Low Engine Oil Pressure
- Engine Oil Filter
- Fluid Overheat, water, oil
- Battery Charging
- Electrical System, Message Fault
- Engine Problem
- Sensor Resistance Value
- Windscreen Wiper Motor
- Pressure Testing (JS330)
- Pressure Testing (JS450/JS460/JS500)
- Introduction, Specifications
- Port Identification
- Dismantling and Assembly
- Dismantling and Assembly (JS330/JS450)
- Specification
- Precautions Before Use
- Spool Location JS330
- Hydraulic Circuit Diagram JS330
- Spool Location JS450/JS460/JS500
- Hydraulic Circuit Diagram JS450/JS460/JS500
- Hydraulic Circuit Diagram JS460/JS500 Tier 2
- Spool Location JS460/JS500 Tier 2
- Operation JS330
- Removal and Replacement - Typical
- Operation JS450/JS460/JS500
- Travel Functions - High Speed
- Middle Speed
- Low Speed
- Linear Travel
- Zero Slewing
- Slew Operation
Section E109 topics
- Slew Brake
- Slew Lock
- Combined Slew and Dipper Closing
- Excavator End Functions - Boom Up
- Boom Down
- Boom Down in L, F Mode
- Boom Down Starting Delay
- Dipper Opening
- Dipper Closing
- Bucket Opening
- Bucket Closing
- Combined Operations
- Cushion Valve - Soft
- Cushion Valve - Hard
- High Dump
- Maximum Flow Rate Cut
- Negative Control
- Hammer/Auxiliary/Merge
- Middle Speed
- Low Speed
- Linear Travel
- Zero Slewing
- Slew Operation
- Slew Brake
- Slew Lock
- Combined Slew and Dipper Closing
- Reverse Protection Valve
- Boom Down
- Boom Down in L, F Mode
- Boom Down Starting Delay
- Dipper Opening
- Dipper Closing
- Bucket Opening
- Bucket Closing
- Combined Operations
- High Dump
- Maximum Flow Rate Cut
- Negative Control
- Hammer/Auxiliary/Merge
- Crusher Circuit
- Travel Circuit
- Multi Function Travel and Boom Up
- Hammer/Auxiliary/Merge
- Neutral Circuit
- Travel Functions - Linear Travel
- Middle Speed
- Boom Up
- Boom Down
- Dipper Out
- Dipper In
- Bucket Opening
- Bucket Closing
- Priority Valves
- Slew Circuit
- Auxilary/Merged Flow
- Hammer
- Introduction, Specification
- Remote Control Valve - Components
- Introduction
- General Information
- Introduction, Technical Data
- Spool Solenoid
- Specifications and Torque Settings
- Precautions During Use
- Bucket Ram Removal and Replacement
- Dipper Ram Removal and Replacement
- Boom Ram Removal and Replacement
- Re-Conditioning
- Maintenance Specifications
- Testing the Hose Burst Check Valve - Arm Ram
- Testing the Hose Burst Check Valve
- Operation JS450
- Operation JS330 and JS460/JS500
- Removal/Replacement
- Dismantling
- Assembly
- Specifications
- Hydraulic Motor Components
- Motor Operating Principles
- Slew Brake Operation
- Inspection
- Slew Motor - Removal and Replacement
- Slew Motor - Dismantling
- Slew Motor - Inspection
- Slew Motor - Assembly
- Slew Reduction Gear - Dismantling
- Slew Reduction Gear - Inspection
- Slew Reduction Gear
- Traction Motor
- Brake Valve
- Parking Brake
- Travel Motor
- Preparation for Use
- Removal and Replacement
- Motor Bleeding
- Traction Motor - JS330
- Exploded View (Motor) - JS330
- Components List (Motor) - JS330
- Exploded View (Gearbox) - JS330
- Components List (Gearbox) - JS330
- Traction Motor - JS450
- Exploded View (Motor) - JS450
- Components List (Motor) - JS450
- Traction Motor Components List - JS460/JS500
- Torque Specifications
- Removal
- Replacement
- Wear Limits
- Exploded drawing
Inside this manual
Real pages from this service manual (675 pages). Open the sample pages (PDF, 409 KB)
- Specifications, page 210: Issue 4*
- Diagram, page 290: Issue 1*
- Troubleshooting, page 520: Hydraulic Rams
- Color page, page 426: Section E
- Foldout diagram (color), page 451: Hydraulics
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 675 pages
Quantity one is the manual described above.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).