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jcb JS300 Service Manual

Tracked excavators - tier 2 jcb dieselmax engine
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Service Manual
JS300, JS330, JS360/370 - Tracked
Excavators - Tier 2 JCB DieselMax
Engine
Section 1 - General Information
Section 2 - Operator's Manual
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Section M - Electronic Data Systems
Publication No.
9813/2750-2
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 2 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 3 Section 1 - General Information Notes: 9813/2750-2 Find manuals at https://best-manuals.com...

  • Page 4: Table Of Contents

    Section 1 - General Information Contents Page No. Introduction Identifying Your Machine ................ 1-1-1 Safety Introduction ..................... 1-2-1 Introduction ..................... 1-3-1 Scope ..................... 1-3-2 Format ....................1-3-3 Left Side, Right Side ................1-3-4 Hydraulic Schematic Codes ..............1-3-5 Routine Maintenance Maintenance Schedules .................
  • Page 5 Section 1 - General Information Contents Page No. 1-ii 1-ii Find manuals at https://best-manuals.com...

  • Page 6: Identifying Your Machine

    Section 1-1 - General Information Introduction Identifying Your Machine For information about identifying your machine and its main components, refer to Section 2, About the Machine, Machine and Component Identification. 1-1-1 9813/2750-2 1-1-1 Find manuals at https://best-manuals.com...
  • Page 7 Section 1-1 - General Information Introduction Identifying Your Machine Page left intentionally blank 1-1-2 9813/2750-2 1-1-2 Find manuals at https://best-manuals.com...
  • Page 8 Section 1-2 - General Information Safety Introduction In this manual and on the machine there are safety notices. The safety notices have different signal words as follows: – DANGER – WARNING – CAUTION – Notice For an explanation of the safety notice signal words, refer to Section 2, Introduction, Safety.

  • Page 9: Safety Introduction

    Section 1-2 - General Information Safety Introduction Page left intentionally blank 1-2-2 9813/2750-2 1-2-2 Find manuals at https://best-manuals.com...

  • Page 10: Use

    Section 1-3 - General Information Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-3-2) K Personnel ( T 1-3-2) K Applications ( T 1-3-2) K Newest Data ( T 1-3-2) K Format ( T 1-3-3) K Left Side, Right Side ( T 1-3-4) K Hydraulic Schematic Codes ( T 1-3-5)

  • Page 11: Scope

    Section 1-3 - General Information Scope Scope Personnel This manual 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...

  • Page 12: Format

    Section 1-3 - General Information Format Format The manual is compiled in sections, the first two are numbered and contain information as follows: General Information - The section includes general information such as torque settings and service tools. Operator Manual - The section contains a copy of the applicable machine Operator Manual.

  • Page 13: Left Side, Right Side

    Section 1-3 - General Information Left Side, Right Side Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. C017280 Fig 1. 1-3-4 9813/2750-2 1-3-4...

  • Page 14: Hydraulic Schematic Codes

    The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.
  • Page 15 Section 1-3 - General Information Hydraulic Schematic Codes Page left intentionally blank 1-3-6 9813/2750-2 1-3-6...
  • Page 16 Section 1-4 - General Information Routine Maintenance Maintenance Schedules This publication contains procedures for carrying out the routine maintenance tasks listed on the maintenance schedules. Refer to Section 2, Maintenance Schedules. The procedures for the daily and weekly (10 and 50 hour) tasks are given in Section 2, Maintenance.

  • Page 17: Routine Maintenance Maintenance Schedules

    Section 1-4 - General Information Routine Maintenance Maintenance Schedules Page left intentionally blank 1-4-2 9813/2750-2 1-4-2...

  • Page 18: General Procedures

    Section 1-5 - General Information General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are;...

  • Page 19: Parking The Machine And Making It Safe

    Section 1-5 - General Information General Procedures Parking the Machine and Making it Safe Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe, refer to Section 2, Maintenance, Maintenance Positions. 1-5-2 9813-2750-2 1-5-2...

  • Page 20: Venting The Hydraulic Pressure

    Section 1-5 - General Information General Procedures Venting the Hydraulic Pressure Venting the Hydraulic Pressure 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 21: Connecting/Disconnecting Hydraulic Hoses

    Section 1-5 - General Information General Procedures Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses 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 22: Battery Disconnection/Connection

    Section 1-5 - General Information General Procedures Battery Disconnection/Connection Battery Disconnection/Connection For the correct procedures to disconnect/connect the battery, refer to Section 2, Maintenance, Electrical System, Battery. 1-5-5 9813-2750-2 1-5-5...

  • Page 23: Removing And Replacing Components

    Make sure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems. Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque.

  • Page 24: Battery Charging System Precautions

    Section 1-5 - General Information General Procedures Battery Charging System Precautions Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. – Ensure that the battery negative terminal is connected to the earthing cable. –...

  • Page 25: Gas Hydraulic Bladder Accumulators

    Section 1-5 - General Information General Procedures Gas Hydraulic Bladder Accumulators Gas Hydraulic Bladder Accumulators Some hydraulic circuits and valve blocks are fitted with gas WARNING hydraulic bladder type accumulators. Use only nitrogen gas to charge accumulators. The Before removing accumulators make sure hydraulic use of any other gas can cause the accumulators to K Venting pressure...
  • Page 26 Section 1-5 - General Information General Procedures Gas Hydraulic Bladder Accumulators Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor.
  • Page 27 Section 1-5 - General Information General Procedures Gas Hydraulic Bladder Accumulators Page left intentionally blank 1-5-10 9813-2750-2 1-5-10...

  • Page 28: Service Consumables

    Section 1-6 - General Information Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available. K Sealing and Retaining Compounds ( T 1-6-2) 1-6-1 1-06-00 Issue 01 1-6-1...

  • Page 29: Sealing And Retaining Compounds

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 30 Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.

  • Page 31: Service Tools Numerical List

    Section 1-7 - General Information Service Tools Numerical List Part Description See Section Number K Pressure Test 'T' Adapters ( T 1-7-9) Pressure Test Points - 'T' Adaptors. K 'T' Adapters ( T 1-7-10) 'T' Adaptors. Female Blanking Caps K Male Cone Blanking Caps ( T 1-7-10) Male Cone Blanking Caps.
  • Page 32 Section 1-7 - General Information Service Tools Numerical List Part Description See Section Number K Jig for Inserting Cylinder Head ( T 1-7-22) Jig for Inserting Cylinder Head. K Seal Ring and Connector Jig ( T 1-7-22) Seal Ring and Connector Jig. K Bush Removal Jig ( T 1-7-23) Bush Removal Jig.

  • Page 33: Tool Detail Reference

    Section 1-7 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 1. 993/68100 Slide Hammer Kit 993/68101 Slide Hammer 993/68107 Bar - M20 x M20 X 800 mm 993/68102 End Stops 993/68108...
  • Page 34 Section 1-7 - General Information Service Tools Tool Detail Reference Fig 7. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will Fig 4. 892/00843 Folding Stand chip the glass edge. Essential for preparing new glass prior to installation.
  • Page 35 Consumable heavy duty cut-out wire used with the glass supplied. extraction tool. Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame.
  • Page 36 Section 1-7 - General Information Service Tools Tool Detail Reference Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-7-7 9813/2750-2 1-7-7...
  • Page 37 Section 1-7 - General Information Service Tools Tool Detail Reference Section C - Electrics Note: Not all service tools are illustrated. Fig 16. 892/00298 Fluke Meter Fig 19. 892/01174 Interconnecting cable, DLA to machine ECU diagnostics socket. Interconnecting cable, DLA to machine ECU diagnostics socket.
  • Page 38 Section 1-7 - General Information Service Tools Tool Detail Reference Section E - Hydraulics Note: Not all service tools are illustrated. Male Adapters - BSP x BSP 1606/2052 3/8 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in. 892/00071 3/8 in.
  • Page 39 Section 1-7 - General Information Service Tools Tool Detail Reference 892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in.
  • Page 40 Section 1-7 - General Information Service Tools Tool Detail Reference 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022...
  • Page 41 Section 1-7 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB 892/00268 Flow Monitoring Unit K Fig 33. ( T ServiceMaster Flow Test Kit. 1-7-12). 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
  • Page 42 Section 1-7 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in ServiceMaster Digital Hydraulic Datalogger Pressure K Fig 35. ( T Test Kit. 1-7-13). 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in...
  • Page 43 Section 1-7 - General Information Service Tools Tool Detail Reference 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 3 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 Test Probe 892/00278...
  • Page 44 Section 1-7 - General Information Service Tools Tool Detail Reference 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 Spanner 75 mm A/F 993/99517 Spanner 85 mm A/F 993/99518 Spanner 90 mm A/F 993/99519...
  • Page 45 Section 1-7 - General Information Service Tools Tool Detail Reference A408900 Fig 42. Socket Box Wrench Note: For disassembly and assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-7-16 9813/2750-2 1-7-16...
  • Page 46 Section 1-7 - General Information Service Tools Tool Detail Reference A408860 Fig 43. Nut Adaptor Note: For disassembly and assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-7-17 9813/2750-2 1-7-17...
  • Page 47 Section 1-7 - General Information Service Tools Tool Detail Reference A408880- C 1 Fig 44. Seal Ring Tool Note: For assembly and disassembly of Swing motor gearbox seal. This tool can not be ordered from JCB. 1-7-18 9813/2750-2 1-7-18...
  • Page 48 Section 1-7 - General Information Service Tools Tool Detail Reference A408890 Fig 45. Stopper Note: For assembly of Swing motor gearbox. This tool can not be ordered from JCB. 1-7-19 9813/2750-2 1-7-19...
  • Page 49 Section 1-7 - General Information Service Tools Tool Detail Reference A408870- C 1 Fig 46. Bearing Rig Note: For removal of Swing motor bearing. This tool can not be ordered from JCB. 1-7-20 9813/2750-2 1-7-20...
  • Page 50 Section 1-7 - General Information Service Tools Tool Detail Reference C118440 Fig 47. 892/00239 Accumulator Gas Charge Kit Use with Hydac bladder type accumulators Kit comprises the following: Pressure gauge Connection hose Mounting bracket (pressure gauge) Gas bottle adaptor (G2) Hydac bladder accumulator adaptor Testing and charging unit Spare seal (accumulator plug)
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