jcb JS300 User manual

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.
World Class
Customer Support
9813/5100-1
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel [phone] Fax [phone]
Service Manual
JS300, JS330, JS370 - Tracked
Excavators - Tier 4i Isuzu 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

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.
World Class
Customer Support
9813/5100-1
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel [phone] Fax [phone]
Section 1
General Information
Service Manual - JS300, JS330, JS370 - Tracked Excavators - Tier 4i Isuzu 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 1 - General Information
1-0 1-0
9813/5100-1
Notes:

Page No.Contents
Section 1 - General Information
1-i 1-i
Introduction
Identifying Your Machine ........................................................................... 1-1
Safety
Introduction ................................................................................................ 1-3
Use
Introduction ................................................................................................ 1-5
Scope ........................................................................................................ 1-6
Format ....................................................................................................... 1-7
Left Side, Right Side .................................................................................. 1-8
Hydraulic Schematic Codes ...................................................................... 1-9
Routine Maintenance
Maintenance Schedules .......................................................................... 1-11
General Procedures
Introduction .............................................................................................. 1-13
Parking the Machine and Making it Safe ................................................. 1-14
Venting the Hydraulic Pressure ............................................................... 1-15
Connecting/Disconnecting Hydraulic Hoses ............................................ 1-16
Battery Disconnection/Connection .......................................................... 1-17
Removing and Replacing Components ................................................... 1-18
Battery Charging System Precautions ..................................................... 1-19
Gas Hydraulic Bladder Accumulators ...................................................... 1-20
Service Consumables
Introduction .............................................................................................. 1-23
Sealing and Retaining Compounds ......................................................... 1-24
Torque Settings
Introduction .............................................................................................. 1-25
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-26
Hydraulic Connections ............................................................................. 1-30
`Positional Type' Hydraulic Adaptors ....................................................... 1-34
Service Tools
Numerical List .......................................................................................... 1-35
Tool Detail Reference .............................................................................. 1-38

Page No.Contents
Section 1 - General Information
1-ii 1-ii

Section 1 - General Information
1-1 1-1
9813/5100-1
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.

Section 1 - General Information
Introduction
Identifying Your Machine
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Section 1 - General Information
1-3 1-3
9813/5100-1
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.
For general safety notices, refer to Section 2,
Introduction, Safety.
For maintenance safety notices, refer to Section 2,
Maintenance, Maintenance Safety.
For safety notices specific to maintenance procedures,
refer to the relevant procedure.
If you do not fully understand a safety notice ask your
employer to explain it.

Section 1 - General Information
Safety
Introduction
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Section 1 - General Information
1-5 1-5
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Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
K Scope ( T 1-6)
K Personnel ( T 1-6)
K Applications ( T 1-6)
K Newest Data ( T 1-6)
K Format ( T 1-7)
K Left Side, Right Side ( T 1-8)
K Hydraulic Schematic Codes ( T 1-9)
K Colour Codes ( T 1-9)

Section 1 - General Information
Use
Scope
1-6 1-6
9813/5100-1
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
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment. Finally, please
remember above all else SAFETY MUST COME FIRST!
Applications
This manual contains data relevant to a range of
machines. Make sure you reference the data for the
correct machine.
Newest Data
From time to time new machines, systems or devices
require the manual to be re-issued. Make sure you have
the newest issue.
Always check the on-line JCB data system for relevant
technical information.

Section 1 - General Information
Use
Format
1-7 1-7
9813/5100-1
Format
The manual is compiled in sections, the first two are
numbered and contain information as follows:
1 General Information - The section includes general
information such as torque settings and service tools.
2 Operator Manual - The section contains a copy of
the applicable machine Operator Manual. Refer to
this section when necessary for information about the
main machine components and controls. Refer also
to the safety and daily / weekly maintenance
information.
The remaining sections are alphabetically coded and deal
with dismantling, overhaul etc. of specific components, for
example:
Each section contains data such as technical data,
descriptions, fault finding and test procedures.
Some sections contain procedures and specifications
for different variants. This happens because of market
requirements, or when the machine specification changes
after a period of time. Where applicable, a table contains
information to help you identify the correct data and
procedures.
AAttachments
B Body and Framework...etc.

Section 1 - General Information
Use
Left Side, Right Side
1-8 1-8
9813/5100-1
Left Side, Right Side
In this manual, 'left' Aand 'right' Bmean your left and right
when you are seated correctly in the machine.
C017280
Fig 1.
A
B

Section 1 - General Information
Use
Hydraulic Schematic Codes
1-9 1-9
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Hydraulic Schematic Codes
Colour Codes
The following colour coding, used on illustrations to denote
various conditions of oil pressure and flow, is standardised
throughout JCB Service Publications.
Red Full Pressure: Pressure generated from operation of a service. Depending on application this
may be anything between neutral circuit pressure and LSRV operating pressure.
Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange Pilot: Oil pressure used in controlling a device (Pilot).
Blue Neural: Neutral circuit pressure.
Green Exhaust:
Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

Section 1 - General Information
Use
Hydraulic Schematic Codes
1-10 1-10
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Section 1 - General Information
1-11 1-11
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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.
Operator tasks are given in Section 2, Maintenance.
Additional service engineer tasks are given in the related
sections of this publication. For example the procedures
for engine related tasks are given in Section K.

Section 1 - General Information
Routine Maintenance
Maintenance Schedules
1-12 1-12
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Section 1 - General Information
1-13 1-13
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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; parking the machine and making it safe, and venting hydraulic pressure.
These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a
cross reference to this section so that you can refer to the detailed procedures.
K Parking the Machine and Making it Safe ( T 1-14)
K Venting the Hydraulic Pressure ( T 1-15)
K Connecting/Disconnecting Hydraulic Hoses ( T 1-16)
K Battery Disconnection/Connection ( T 1-17)
K Removing and Replacing Components ( T 1-18)
K Battery Charging System Precautions ( T 1-19)
K Gas Hydraulic Bladder Accumulators ( T 1-20)

Section 1 - General Information
General Procedures
Parking the Machine and Making it Safe
1-14 1-14
9813-5100-1
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.

Section 1 - General Information
General Procedures
Venting the Hydraulic Pressure
1-15 1-15
9813-5100-1
Venting the Hydraulic Pressure
!MWARNING
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.
HYD-1-5
For the correct procedures to vent the hydraulic pressure,
refer to Section 2, Maintenance, Hydraulic System,
General, Discharge.