jcb JCB305 Service Manual

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SERVICE MANUAL

EXCAVATOR

JCB305, JS305

EN - 9813/6700 - ISSUE 1 - 12/2016

This manual contains original instructions, verified by

the manufacturer (or their authorized representative).

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.

www.jcb.com

Foreword

The Operator's Manual

You and others can be killed or seriously injured

if you operate or maintain the machine without

first studying the Operator's Manual. You must

understand and follow the instructions in the

Operator's Manual. If you do not understand

anything, ask your employer or JCB dealer to

explain it.

Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you

do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the

Operator's Manual immediately if it is lost, damaged

or becomes unreadable.

Contents

01 - Machine

03 - Attachments, Couplings and Load

Handling

06 - Body and Framework

09 - Operator Station

Heating,

Conditioning (HVAC)

15 - Engine

18 - Fuel and Exhaust System

21 - Cooling System

27 - Driveline

30 - Hydraulic System

33 - Electrical System

72 - Fasteners and Fixings

75 - Consumable Products

78 - After Sales

Ventilating

and

Air-

Table of Contents

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Summary of Contents for jcb JCB305

Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
Page 2: Check (Condition)
15 - Engine 33 - Connecting Rod 06 - Big-End Bearing Check (Condition) Remove and Install Special Tools 1. Check the bearing shell surfaces for signs of Description Part No. Qty. Tool damage and excessive wear. Category Special Torque 993/70111 2.
Page 3 15 - Engine 33 - Connecting Rod 06 - Big-End Bearing Figure 148. Figure 149. 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 3. Lift out the bearing shells from the bearing caps. Carefully rotate the crank to disengage from the connecting rods and get access to the upper 1 Big-end bearing cap bearing shells.
Page 4: After Installation
15 - Engine 33 - Connecting Rod 06 - Big-End Bearing 3. Install the upper bearing shell to the connecting rod. Lubricate the bearing shell with clean engine oil. 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with clean engine oil.
Page 5: Technical Data
15 - Engine 36 - Piston 00 - General Technical Data Table 66. Engine 444 - SE Engine 444 - excluding SE en- 448, 672 gine Gudgeon pin bore diame- - min. 4.0008mm 40.01mm 42.008mm - max. 40.013mm 40.015mm 42.013mm Piston ring clearance - Top ring Half keystone ring...
Page 6: Component Identification
15 - Engine 36 - Piston 00 - General Component Identification Figure 152. Piston 2 Piston ring - compression No.1 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod 7 Retaining circlip (x2) Piston pin Connecting rod - longest side...
Page 7: Operation
15 - Engine 36 - Piston 00 - General Operation The groove around the diameter of the upper main top of the pistons. Oil spray also enters the small end bearing shells allows oil transfer to an oil jet located bearing bushes via a feed hole on the top of each in the crankcase bearing saddle.
Page 8 15 - Engine 36 - Piston 00 - General Check (Condition) Calibrate 1. Check the piston for signs of damage and Piston Height Measurement Above excessive wear. Measure the piston skirt Cylinder Block- DTI Method diameter, piston pin bore and the clearance in the piston ring grooves to confirm they are within Refer to engine, piston, technical data, (PIL service limits.
Page 9 15 - Engine 36 - Piston 00 - General Figure 154. DTI Measurement 5. Calculate the average of the 2 readings to give a figure of the piston height above the cylinder block. 5.1. If the reading obtained is lower than zero, the connecting rod may be bent.
Page 10 15 - Engine 36 - Piston 00 - General Remove and Install Before Removal 3. Get access to the engine. 4. Disconnect and remove the fuel pipes from the The following procedure is for one piston and injectors, refer to (PIL 18-96). connecting rod assembly.
Page 11 15 - Engine 36 - Piston 00 - General Figure 156. 1 Piston 2 Piston ring 3 Connecting rod X Longest side of connecting rod 15 - 140 9813/6700-1 15 - 140...
Page 12 15 - Engine 36 - Piston 00 - General Remove The piston and connecting rod assemblies are removed through the top of the crankcase. 1. Use a suitable scraper and wire wool to clean off the carbon deposits from around the top of the cylinder bore.
Page 13: Disassemble And Assemble
15 - Engine 36 - Piston 00 - General Disassemble and Assemble Dismantle Carefully remove the piston rings from the piston. To avoid damage or distortion to the rings, use a 1. Clamp the connecting rod in a vice. Take care not suitable piston ring expander tool.
Page 14 15 - Engine 36 - Piston 00 - General Figure 157. Piston 2 Piston ring - compression No.1 Piston ring - compression No.2 4 Piston ring - oil control ring 4a Spiral wire - oil control ring 5 Connecting rod Piston pin 7 Retaining circlip (x2) Connecting rod - longest side...
Page 15 15 - Engine 36 - Piston 00 - General Assemble 1. The assembly procedure is the opposite of the disassemble procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3.
Page 16: Piston Ring
15 - Engine 36 - Piston 03 - Piston Ring 03 - Piston Ring Introduction Gas sealing inside the piston is achieved by the use of piston rings. The rings are loosely installed into grooves in the piston. The rings are split at a point in the rim, to allow them to press against the cylinder with a light spring pressure.
Page 17 15 - Engine 42 - Rocker and Fittings 00 - General Technical Data Table 67. Rocker Levers, Rocker Shafts and Tappets Data Valve clearances measured at the valve bridge piece tip of the rockers (measured cold): - Inlet 0.19–0.27mm - Exhaust 0.56–0.64mm Rocker clearances measured at the adjusting screw tip of the rockers (measured cold):...
Page 18 15 - Engine 42 - Rocker and Fittings 00 - General Component Identification Figure 158. 1 Rocker assembly Rocker shaft fixing bolts (x11) 3 Rocker shaft - oil feed pedestal fixing bolt (x1) Pedestals (x11) 5 Oil feed pedestal (x1) Rockers - exhaust (x6) 7 Rockers - inlet (x6) Wave washers (x6)
Page 19 15 - Engine 42 - Rocker and Fittings 00 - General Operation When the camshaft lobe raises the outside of the rocker arm is permitted to return due to the camshafts rocker arm, the inside presses down on the valve rotation, the inside rises to allow the valve spring to stem to open the valve.
Page 20 15 - Engine 42 - Rocker and Fittings 00 - General Check (Condition) 1. Check the rocker shaft and rocker bushings for signs of damage and excessive wear. Measure the rocker shaft diameter and rocker bearing bushes to confirm they are within service limits, refer to Technical Data (PIL 15-42).
Page 21 15 - Engine 42 - Rocker and Fittings 00 - General Remove and Install Before Removal 2. Get access to the engine. 3. Disconnect and remove the fuel pipes from the 1. Make sure that the engine is safe to work on. If fuel injectors, refer to Fuel pipes (PIL 18-96).
Page 22: Before Installation
15 - Engine 42 - Rocker and Fittings 00 - General Remove 1. Remove the rocker shaft fixing bolts. DO NOT withdraw the bolts. Lift the rocker shaft assembly from the cylinder head complete with pedestals still attached. Important: Keep all pedestals and fixing bolts in their original positions.
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Js305