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jcb JS300, Service Manual

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Summary of Contents for JS300

Page 1: ...ng 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 Operat...

Page 2: ...9813 7500 2 Notes Find manuals at https best manuals com ...

Page 3: ...olume 1 JS300 JS330 JS370 EN 9813 7500 SERVICE MANUAL Volume 2 JS300 JS330 JS370 EN 9813 7500 SERVICE MANUAL Volume 3 JS300 JS330 JS370 EN 9813 7500 SERVICE MANUAL Volume 4 JS300 JS330 JS370 EN 9813 7500 Find manuals at https best manuals com ...

Page 4: ...Notes 9813 7500 2 Find manuals at https best manuals com ...

Page 5: ...fety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 15 01 06 06 Using the Manual 01 16 01 09 Description 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 01 33 Cleaning 01 33 00 General 01 29 Find manuals at https best man...

Page 6: ...ief Valve DEF Diesel Exhaust Fluid ECU Electronic Control Unit FEAD Front End Accessory Drive HVAC Heating Ventilation Air Conditioning MRV Main Relief Valve PIL Parts Identification List PPE Personal Protective Equipment Find manuals at https best manuals com ...

Page 7: ...ty Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 Find manuals at https best manuals com ...

Page 8: ...Notes 01 2 9813 7500 2 01 2 Find manuals at https best manuals com ...

Page 9: ... hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them Do not work with the machine until you are sure that you can control it Do not start ...

Page 10: ...tion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in machine damage The safety alert system shown also helps to identify important safety messages in this manual and on the mach...

Page 11: ...aware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switc...

Page 12: ...aulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or rotted O ...

Page 13: ...ecomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area with 10 cal...

Page 14: ...ly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machin...

Page 15: ...y Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Controls You or o...

Page 16: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Page 17: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Page 18: ...vel ground with the upper structure parallel to the undercarriage 2 If applicable lower the dozer blade 3 Lower the excavator so the dipper is flat on the ground Refer to Figure 2 Figure 2 4 Stop the engine 5 Remove the ignition key 6 Discharge the hydraulic pressure Refer to PIL 30 00 00 7 Isolate the battery to prevent the accidental operation of the engine Refer to PIL 33 03 03 ...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 7500 2 01 13 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 15 01 06 06 Using the Manual 01 16 ...

Page 20: ...Notes 01 14 9813 7500 2 01 14 ...

Page 21: ...l 03 Model and Serial Number 01 15 9813 7500 2 01 15 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To JS300 2491541 JS330 2491581 JS370 2491607 ...

Page 22: ...cable information sets are included within the same PIL reference Headings are included to identify which information is for which variant Make sure you use the correct information Systems Descriptions Where relevant procedures are included with full systems descriptions These describe how the machine responds to operator inputs from devices such as control levers electrical switches and electroni...

Page 23: ... If necessary replace them with new ones During assembly use new sealing elements such as gaskets and O rings Torque Tightening Use the torque tightening values contained in the individual procedures Remove and Install Disassemble and Assemble etc If no values are specified use the standard torque tightening values Refer to PIL 72 00 Always use the correct grade of fastener Consumable Products Som...

Page 24: ...e Control System PIL 18 00 30 Throttle control system fault Refer to Electro Hydraulic Throttle Control System PIL 18 00 40 Variable displacement hydraulic pump fault Refer to Fault Finding PIL 30 12 00 Fuel pump fault Refer to Check Operation PIL 18 21 00 Fuel exhaust system fault Refer to Fault Finding PIL 18 00 00 Fuel injection fault Refer to Fault Finding PIL 18 18 00 Engine sensor fault Refe...

Page 25: ...efer to Check Condition PIL 06 24 03 1 Check the slew service cycle times Refer to Check Operation PIL 30 00 15 2 Check the applicable service spools Table 8 Travel service does not operate as expected 1 2 Cause Remedy Servo pressure not correct Refer to Check Pressure PIL 30 00 15 Excavator control valve fault Refer to Fault Finding PIL 30 50 00 3 Travel system fault Refer to Fault Finding PIL 27...

Page 26: ...01 Machine 09 Description 01 20 9813 7500 2 01 20 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22 ...

Page 27: ...2 01 21 12 Main Component Locations Introduction Main Assemblies Figure 3 A B C D F G H J K E M L A Bucket attachment B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram J Operator station K Counterweight L Undercarriage M Revolving chassis ...

Page 28: ...e 4 Upper structure B A D F E C J G H A Breather hydraulic tank B Cover suction strainer C Cover return filter D Excavator control valve block E Filter rockbreaker return line F Filter in line cushion valve G Oil level dipstick slew motor gearbox H Oil filler port slew motor gearbox J Oil drain plug slew motor gearbox access from below the machine ...

Page 29: ...01 Machine 09 Description 15 Service Point Locations 01 23 9813 7500 2 01 23 Figure 5 Hydraulic compartment A B C A Servo filter element B In line drain filter element C Hydraulic oil level gauge ...

Page 30: ...B H K L J A Exhaust system B Engine oil level dip stick C Fuel filters D FEAD Front End Accessory Drive belt E Engine oil filler port F Coolant expansion bottle G Fan Belt H Engine oil drain point access from below the machine J Engine oil filter K DEF Diesel Exhaust Fluid tank filler L DEF tank drain point access from below the machine ...

Page 31: ...500 2 01 25 Figure 7 Battery cooling compartment D E H B A C G F A Safety air filter element B Primary air filter element C Scavenge intake D Battery compartment E Cooling pack compartment F Fuel cooler matrix G Drain plug coolant access under machine H Cooling pack ...

Page 32: ...01 Machine 09 Description 15 Service Point Locations 01 26 9813 7500 2 01 26 Figure 8 Hydraulic compartment A B A Pre filter fuel filter B Fuel shut off valve ...

Page 33: ...01 Machine 33 Cleaning 01 27 9813 7500 2 01 27 33 Cleaning Contents Page No 01 33 00 General 01 29 ...

Page 34: ...Notes 01 28 9813 7500 2 01 28 ...

Page 35: ...render the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surroun...

Page 36: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe Stop the machine and let it cool for at least one hour Do not try to c...

Page 37: ...7500 2 2016 10 06 03 Attachments Couplings and Load Handling Contents Page No Acronyms Glossary 03 2 03 00 Attachments 03 00 00 General 03 3 03 10 Excavator Arm Quickhitch 03 10 06 Hydraulic Quickhitch 03 7 ...

Page 38: ...9813 7500 2 2016 10 06 Acronyms Glossary CAN Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit LED Light Emitting Diode ...

Page 39: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 7500 2 03 1 00 Attachments Contents Page No 03 00 00 General 03 3 ...

Page 40: ...Notes 03 2 9813 7500 2 03 2 ...

Page 41: ...ty the gradients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic system mounting arrangements and safe load requirements Attachments which are not designed for use with this machine may cause damage and cr...

Page 42: ...oad and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and the area around it are clear of other people Anyone on or close to the machine could fall and be crushed by the attachments or get caught in the linkages DANGER Using the forks alone as a working pla...

Page 43: ...03 Attachments Couplings and Load Handling 10 Excavator Arm Quickhitch 03 5 9813 7500 2 03 5 10 Excavator Arm Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7 ...

Page 44: ...Notes 03 6 9813 7500 2 03 6 ...

Page 45: ...a normal attachment at the dipper and tipping link A hydraulically operated latch mechanism enables quickhitch compatible attachments to be installed and removed without the need to leave the cab The electro hydraulic control system ensures the correct positioning of the boom and dipper before the quickhitch latch mechanism can be operated Figure 9 Typical hydraulic quickhitch installation C B D A...

Page 46: ...on Figure 10 A A B B C A Dipper position sensor switch housing B Boom position sensor switch housing C LED Light Emitting Diode indicator Figure 11 A A A Solenoid valve located in the hydraulic compartment on the chassis Figure 12 Harness con nectors C158 C157 C156 Figure 13 Harness connector C121 Figure 14 Harness connector C095 X2 green ...

Page 47: ... 15 to cancel the request When the HECU receives the input from the switch it will inform the DECU Display Electronic Control Unit via the CAN Controller Area Network bus of a quickhitch unlock request The DECU will then display the boom dipper padlock symbol As the boom and dipper position sensors connect the HECU to ground the applicable symbol will change to green to show that either boom or di...

Page 48: ...OINT INT EP07 ECU HYDRAULIC CONTROL ECU J2 SENSOR ALIGNMENT ARM C154 C158 SENSOR ALIGNMENT BOOM C157 SENSOR PRESSURE QUICK HITCH C156 BUCKET CROWD SELECTED REVOLVER EARTH STUD EP03 REVOLVER EARTH STUD EP03 A Quickhitch switch pressed B Bucket crowd position set C121 Switch quickhitch C154 HECU Hydraulics Electronic Control Unit connector J2 C156 Sensor quickhitch pressure C157 Sensor boom alignmen...

Page 49: ...U J2 C154 ECU HYDRAULIC CONTROL ECU J1 C153 JOYSTICK RH HANDLE C095 SOLENOID QUICK HITCH C155 LIGHT QUICK HITCH BOOM STATUS C085 Q H BUTTON PRESSED CAB BASE EARTH POINT INT EP07 REVOLVER EARTH STUD EP03 REVOLVER EARTH STUD EP03 A Quickhitch joystick control switch pressed C095 Joystick control switch quickhitch C153 HECU connector J1 C154 HECU connector J2 C155 Solenoid quickhitch control valve ...

Page 50: ...Notes 03 12 9813 7500 2 03 12 ...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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