jcb JS300 Tracked Excavator Manuals

Manuals and User Guides for jcb JS300 Tracked Excavator. We have 4 jcb JS300 Tracked Excavator manuals available for free PDF download: Service Manual, Operator's Manual

jcb JS300 Service Manual (1135 pages)

Tracked Excavators - Tier 4i Isuzu Engine

Brand: jcb | Category: Compact Loader | Size: 84.89 MB

Table of Contents

69
- Front Lower Window Wiper
  93
- Interior Switches
  94
- Ignition Switch
  94
- Cab Interior Light
  94
- Operation Introduction General
  96
- Operating Safety
  97
- General
  97
- Worksite Safety
  99
- Risk Assessment
  100
- Walk-Around Inspection
  102
- General
  102
- Entering and Leaving the Operator Station
  103
- General
  103
- Emergency Exit
  105
- Doors
  106
- Operator Door
  106
- Windows
  108
- Front Window
  108
- Side Window
  109
- Sun Visor/Sunblind
  111
- Sunblind
  111
- Before Starting the Engine
  113
- General
  113
- Operator Seat
  115
- General
  115
- Suspension Seat
  115
- Heated Seat Controls
  117
- Seat Ventilation Controls
  117
- Seat Belt
  118
- General
  118
- Inertia Reel Seat Belt
  118
- Static Seat Belt
  119
- General
  122
- Mirrors
  122
- Starting the Engine
  127
- General
  127
- Immobiliser
  128
- Warming up
  129
- Stopping and Parking
  131
- General
  131
- Preparing for Worksite Travel
  132
- General
  132
- Preparing for Travel
  132
- Beacon
  133
- Locks
  134
- General
  134
- Control Lock
  134
- Drive Controls
  136
- Track Controls
  136
- Travel Speed Selector
  137
- Instruments
  139
- General
  139
- Instrument Panel
  140
- Getting the Machine Moving
  166
- General
  166
- Driving the Machine
  169
- General
  169
- Towing Other Equipment
  170
- Excavator Arm Controls
  171
- General
  171
- Control Layouts
  171
- Operating Levers/Pedals
  171
- Auxiliary Circuit Controls
  179
- Lifting and Loading
  182
- General
  182
- Load Charts
  182
- Overload Warning System
  183
- Preparing to Use the Excavator Arm
  185
- Lifting with the Excavator Arm
  185
- General
  185
- Working with the Excavator Arm
  185
- Digging
  186
- Changing the Bucket Linkage
  191
- Dipper Stroke Limiter
  192
- Slopes
  195
- General
  195
- Driving on Slopes
  195
- Working on Slopes
  197
- Air-Conditioning Controls
  199
- General
  199
- Heating, Ventilating and Air-Conditioning (HVAC)
  199
- Power Sockets
  202
- Auxiliary Power Socket
  202
- Battery Isolator
  203
- General
  203
- Fire Extinguisher
  204
- General
  204
- Getting the Machine Unstuck
  206
- Moving a Disabled Machine
  206
- General
  206
- Jump-Starting the Engine
  207
- Retrieval
  208
- Excavator Arm (Emergency Operation)
  208
- Lifting the Machine
  210
- General
  210
- Transporting the Machine
  212
- General
  212
- Loading the Machine Onto the Transporting Vehicle/Trailer
  212
- Unloading the Machine from the Transporting Vehicle/Trailer
  216
- Operating Environment
  217
- General
  217
- Operating in Low Temperatures
  217
- Operating in High Temperatures
  217
- Cab Filters
  218
- Filling the Tank
  219
- General
  219
- Low Fuel Levels
  219
- Refuelling
  219
- Attachments
  222
- Working with Attachments
  222
- Introduction
  222
- Attachments for Your Machine
  222
- Connecting/Disconnecting Hydraulic Hoses
  223
- Impact Protection
  226
- Direct-Mounted Attachments
  227
- General
  227
- Quickhitch
  230
- Excavator Arm Quickhitch
  230
- Buckets
  233
- General
  233
- Bucket Teeth
  233
- General
  238
- Preparation
  238
- Cleaning
  238
- Preservation and Storage
  238
- Checking for Damage
  240
- General
  240
- Storage
  241
- General
  241
- Put into Storage
  241
- During Storage
  241
- Take out of Storage
  242
- Livelink
  243
- Anti-Vandal Guards
  243
- Security
  243
- Construction Equipment Security and Registration Scheme (CESAR)
  243
- JCB Plantguard
  243
- General
  243
- Maintenance Introduction General
  246
- Owner/Operator Support
  246
- Service/Maintenance Agreements
  246
- Obtaining Spare Parts
  247
- General
  248
- Maintenance Safety
  248
- Fluids and Lubricants
  249
- Maintenance Schedules
  252
- General
  252
- How to Use the Maintenance Schedules
  252
- Maintenance Intervals
  252
- Pre-Start Cold Checks, Service Points and Fluid Levels
  254
- Functional Tests and Final Inspection
  257
- Maintenance Position (Excavator Arm Lowered)
  259
- General
  259
- Maintenance Positions
  259
- Service Points
  260
- General
  260
- Access Apertures
  266
- General
  266
- Battery Cover
  266
- Engine Compartment Cover
  266
- Hydraulic Compartment Cover
  267
- Radiator Cover
  268
- Tools
  270
- Toolbox
  270
- General
  270
- Lubrication
  271
- General
  271
- Preparation
  271
- Attachments
  272
- General
  272
- Slew Ring Bearings
  273
- Body and Framework
  273
- General
  273
- Pivot Pins
  274
- Operator Station
  276
- General
  276
- Operator Protective Structure
  276
- Seat
  278
- Seat Belt
  278
- Controls
  279
- Engine
  280
- General
  280
- Oil
  280
- Drive Belt
  282
- Air Filter
  283
- General
  283
- Pre-Cleaner
  283
- Dust Valve
  283
- Fuel System
  284
- General
  284
- Tank
  285
- Fuel Filter
  286
- Water Separator
  287
- Fuel Pump Filter
  289
- Cooling System
  290
- General
  290
- Coolant
  290
- Cooling Pack
  291
- General
  292
- Steel
  293
- Idler Wheels
  294
- Rollers
  294
- Track Gearbox
  295
- Oil
  295
- Hydraulic System
  296
- General
  296
- Services
  297
- Oil
  297
- Cylinder Rams
  298
- Electrical System
  299
- General
  299
- Battery
  299
- Battery Isolator
  300
- Fuses
  301
- Relays
  302
- Window Washer
  303
- Miscellaneous
  304
- Fire Extinguisher
  304
- Technical Data
  306
- Static Dimensions
  306
- General
  306
- Dimensions
  307
- Weights
  312
- Excavator Arm Dimensions and Performance
  314
- Performance Dimensions
  314
- Driving Performance
  331
- Noise Emissions
  332
- General
  332
- Noise Data
  332
- Vibration Emissions
  333
- General
  333
- Vibration Data
  334
- Fuel
  337
- General
  337
- Fluids, Lubricants and Capacities
  337
- Coolant
  339
- Torque Values
  341
- General
  341
- Electrical System
  348
- General
  348
- Fuses
  348
- Relays
  350
- Tracks
  351
- General
  351
- Declaration of Conformity
  352
- General
  352
- Data
  352
Section B - Body and Framework

368
- Heater/Air Conditioning SYSTEM
  370
- Introduction
  370
- Related Topics
  371
- Specifications
  372
- Operation Overview
  373
- Electrical Operation and Schematics
  381
- Fault Finding
  385
- HVAC Unit
  390
- Introduction
  390
- Related Topics
  391
- Removal and Replacement
  392
- Air Conditioning Condensor
  394
- Introduction
  394
- Related Topics
  395
- Removal and Replacement
  396
- Air Conditioning Compressor
  398
- Introduction
  398
- Related Topics
  399
- Removal and Replacement
  400
- Cab
  402
- Introduction
  402
- Related Topics
  403
- Cab Structure
  404
- Cab Panel Removal
  412
- Routine Maintenance Procedures
  416
- Scheduled Tasks
  416
- Doors and Locks
  417
- Excavator Lever and Pedal Locks
  418
- Swing Ring Pinion and Gear Teeth
  419
- Fit for Purpose Test
  420
- Cab Heater/Air-Conditioning Filter
  421
Section C - Electrics

424
- Overview and Schematics Circuit Symbols
  426
- Circuit Concepts
  428
- Using a Multimeter
  431
- Schematic Diagrams
  435
- Fuses and Relays
  456
- Introduction
  456
- Related Topics
  457
- Introduction
  458
- Cab Fuse and Relay Box - Connector Identification
  459
- Electronic Controllers
  460
- Introduction
  460
- Related Topics
  461
- Canbus System
  462
- Machine Electronic Control Unit (MECU
  465
- Hydraulic Electronic Control Unit (HECU
  469
- Display ECU (DECU
  473
- Engine ECU
  478
- Testing of ECU Inputs + Outputs
  482
- Engine and Power Control
  484
- Introduction
  484
- Related Topics
  485
- Battery Power Supply and Distribution
  486
- Ignition Power Supply and Distribution
  491
- Engine Start/Stop
  493
- Engine Cranking
  495
- Engine Throttle and Power Mode Control
  498
- Engine Cold Idle
  507
- Engine Fuel Lift Pump
  508
- Barometric Air Pressure Sensor
  509
- Fuel Filter Pressure Sensor
  510
- TMAF Sensor
  511
- Ambient Air Temperature Sensor
  512
- Engine Exhaust after Treatment
  513
- Engine Automatic Warm up
  529
- Engine Automatic Idle
  531
- Electro Viscous Fan
  532
- Engine Coolant Level Switch
  536
- Vacuum Switch
  539
- Fuel Level Sensor
  541
- Refuelling Pump
  544
- Cab Systems and Lighting
  548
- Introduction
  548
- Related Topics
  549
- Camera System
  550
- Standard Work Lights
  552
- Cab Work Lights
  554
- Beacon
  556
- Horn
  558
- Wipers and Washers
  560
- Cab Interior Lamp
  564
- 24 To 12 Volt Converter
  566
- Charging System
  570
- Introduction
  570
- Related Topics
  571
- Description
  572
- Alternator
  574
- Test Procedures
  575
- Harness Systems
  578
- Installation and Interconnections
  578
- Earth Points
  583
- Harness Drawing List
  585
- Drawings
  587
- Connector Codes
  611
- Wire Numbers and Functions
  614
- Wiring Harness Repair
  616
- Battery
  620
- Introduction
  620
- Related Topics
  621
- Maintenance
  622
- Test Procedures
  623
- Disconnection and Connection
  624
- Removal and Replacement
  625
- Introduction
  626
- Machine Diagnostic Modes
  626
- Related Topics
  627
- Selecting the Diagnostic Modes
  628
- Fault Code System
  632
- Introduction
  632
- Related Topics
  633
- Operation Overview
  634
- Engine 'P' Codes
  637
- Cab Area 'B' Codes
  638
- Chassis 'C' Codes
  639
- Canbus 'U' Codes
  640
- Introduction
  642
- Servicemaster Tools Set
  642
- Related Topics
  643
- Tools Suites
  644
- Diagnostics Connectors
  646
- Servicemaster Machine Selection
  647
- Routine Maintenance Procedures
  648
- Scheduled Tasks
  648
- Starter Motor
  649
- Alternator
  650
- Battery Maintenance
  651
- Overload Warning System
  654
Section E - Hydraulics

658
- Introduction
  662
- Schematics
  662
- Systems and Schematics
  662
- Servo Line (Machine
  672
- Servo Line (Cab
  674
- Servo/Pilot Pressure and Return Line
  675
- Hydraulic System
  678
- Introduction
  678
- Related Topics
  679
- Specifications
  680
- Hydraulic Operation and Schematics
  685
- Hydraulic Pump/Regulator
  718
- Introduction
  718
- Hydraulic Pump Operation
  719
- Hydraulic Pump Removal and Replacement
  723
- Hydraulic Pump Dismantling and Assembly
  725
- Regulator Dismantling and Assembly
  731
- Coupling
  738
- Hydraulic Control Valve
  739
- Introduction
  739
- Related Topics
  740
- Layout
  741
- Hydraulic Control Levers
  757
- Introduction
  757
- Related Topics
  758
- Operation
  759
- Removal and Replacement
  761
- Dismantling and Assembly
  763
- Introduction
  769
- Travel Pedal Valve
  769
- Related Topics
  770
- Removal and Replacement
  771
- Dismantling and Assembly
  773
- Introduction
  777
- Solenoid Valve Block
  777
- Related Topics
  778
- Operation
  779
- Removal and Replacement
  783
- Dismantling and Assembly
  784
- Introduction
  787
- Swing Motor
  787
- Related Topics
  788
- Motor Operating Principles
  789
- Swing Brake Operation
  790
- Swing Motor Configuration
  791
- Introduction
  811
- Swing Gearbox
  811
- Related Topics
  812
- Reduction Gear Structure and Working Principles
  813
- Dismantling and Assembly
  814
- Introduction
  831
- Rotary Coupling
  831
- Operation
  832
- Removal and Replacement
  833
- Dismantling
  835
- Assembly
  838
- Hydraulic Rams
  842
- Introduction
  842
- Related Topics
  843
- Precautions During Use
  844
- Removal and Replacement
  846
- Dismantling and Assembly
  864
- Maintenance Specifications
  876
- Introduction
  878
- Shuttle Valve
  878
- Related Topics
  879
- Removal and Replacement
  880
- Dismantling and Assembly
  881
- Cushion Valve
  884
- Introduction
  884
- Related Topics
  885
- Operation
  886
- Removal and Replacement
  891
- Dismantling and Assembly
  892
- Hydraulic System Fault Finding
  894
- Introduction
  894
- Related Topics
  895
- Hydraulic Contamination
  896
- Main Control Valve
  898
- Relief Valve
  899
- Hydraulic System
  900
- Slew Motor
  901
- Hydraulic Pump
  903
- Hydraulic Rams
  904
- Fault Finding Tests
  909
- Test 001: Testing Negative Control Signal
  911
- Test 002: Test Max Flow Signal
  913
- Test 003: Testing Main Pump Pressure
  914
- Test 004: Testing Horsepower Control
  916
- Test 005: Checking the Operation of the Main Hydraulic Spool
  917
- Test 006: Test the Pressure Switches
  919
- Test 007: Testing Engine Speed Settings
  920
- Test 008: Testing Machine Cycle Times
  921
- Test 011: Testing Swing Brake Pressure
  925
- Test 012: Testing Track Motor Relief Valve Settings
  926
- Test 013: Testing Track Motor Drain Line Flow Rate
  927
- Test 014: Testing the High Speed Tracking Setting
  928
- Test 015: Testing the Low Speed Tracking Setting
  929
- Test 016 - Flow Testing Hydraulic Pumps - Record Sheet
  930
- Test 017: Testing Swing Bearing
  931
- Ram Creep Tests - All Services
  934
- Hydraulic System Test Procedures
  936
- Introduction
  936
- Related Topics
  937
- Pressure Testing - General
  938
- Pressure Relief Valve Location
  942
- Main Relief Valve (MRV) Pressure
  944
- Servo Relief Pressure
  946
- Auxiliary Relief Valves
  947
- Slew Motor Pressure Relief
  953
- Travel Motor Relief Pressure
  955
- Routine Maintenance Procedures
  956
- Scheduled Tasks
  956
- Service Points
  957
- Hydraulic Oil
  960
- Hydraulic Tank Breather
  961
- Return Filter
  962
- Drain Filter
  963
- Suction Strainer
  964
- Cushion Valve Filter
  965
- Major Component Mounting Bolts
  966
- Servo Filter Element
  967
- Relief Valves
  968
- Oil Cooler
  969
- Swing Gearbox
  970
- Swing Brake
  972
Section F - Transmission

976
- Technical Data
  978
- Travel Equipment
  978
- Introduction
  980
- Traction Motor / Reduction Gear
  980
- Description
  981
- Operation
  982
- Removal and Replacement
  992
- Dismantling
  997
- Inspection
  1005
- Assembly
  1007
- Start up and Running in
  1013
- Introduction
  1016
- Reduction Gear
  1016
- Dismantling and Assembly
  1017
- Fault Finding
  1033
- Introduction
  1033
- Transmission
  1034
- Routine Maintenance Procedures
  1040
- Scheduled Tasks
  1040
- Track Gearbox
  1041
- Track Plate Bolts
  1042
Section J - Track and Running Gear

1046
- Introduction
  1048
- Track and Running Gear
  1048
- Related Topics
  1049
- Torque Specifications
  1051
- Idler Wheel and Recoil Unit
  1052
- Introduction
  1052
- Related Topics
  1053
- Removal
  1054
- Replacement
  1056
- Idler Wheel
  1058
- Introduction
  1058
- Related Topics
  1059
- Dismantling
  1060
- Assembly
  1062
- Introduction
  1064
- Recoil Unit
  1064
- Dismantling and Assembly
  1065
- Grease Cylinder
  1066
- Introduction
  1066
- Related Topics
  1067
- Removal and Replacement
  1068
- Dismantling and Assembly
  1071
- Drive Sprocket
  1072
- Introduction
  1072
- Related Topics
  1073
- Removal and Replacement
  1074
- Introduction
  1076
- Top Roller
  1076
- Related Topics
  1077
- Removal
  1078
- Replacement
  1079
- Dismantling
  1080
- Assembly
  1083
- Bottom Roller
  1086
- Introduction
  1086
- Related Topics
  1087
- Removal
  1088
- Replacement
  1089
- Dismantling
  1090
- Assembly
  1093
Section K - Engine

1098
- General
  1100
- Technical Data
  1100
- Engine Mounts
  1101
- Engine Error Codes
  1102
- Electrical Components and Connections
  1109
- Introduction
  1109
- Engine Components
  1110
- Engine Controller and Harness Specifications
  1117
- Routine Maintenance
  1127
- Scheduled Tasks
  1127
- Coolant (Change
  1128
- Fan Belt Tension (Check
  1130
- Fan Belt (Replace
  1131
- Air Filters (Change
  1132
- Diesel Particulate Filter (Clean
  1134
- Maximum no Load Speed
  1135

jcb JS300 Operator's Manual (31 pages)

Brand: jcb | Category: Excavators | Size: 1.38 MB

Table of Contents
4
Acronyms Glossary
11
Introduction
12
About this Manual
12
Model and Serial Number
12
Using the Manual
12
Left-Hand Side, Right-Hand Side
12
Cross References
12
Safety
13
Safety - Yours and Others
13
Safety Warnings
13
General Safety
14
Clothing and Personal Protective Equipment (PPE)
15
About the Product
16
Introduction
16
General
16
Name and Address of the Manufacturer
16
Product Compliance
16
Description
17
General
17
Intended Use
17
Log Moving/Object Handling
17
Optional Equipment and Attachments
17
Danger Zone
17
Main Component Locations
18
Product and Component Identification
19
Machine
19
Engine
20
Operator Protective Structure
21
Safety Labels
23
General
23
Safety Label Identification
23
Operator Station
26
Component Locations
26
Interior Switches
27
Ignition Switch
27
Cab Interior Light
27
Console Switches
29
General
29
Work Lights
29
Beacon
29
Seat Heater
29
Seat Ventilation
30
Control Locks
30
Excavator Arm Quickhitch
30
Radio Mute
30
Engine Stop Switch
30
Manual Regeneration
30
Slew Lock
30

jcb JS300 Service Manual (51 pages)

Tracked Excavators - Tier 2 JCB DieselMax Engine

Brand: jcb | Category: Excavators | Size: 1.39 MB

Table of Contents
4
Identifying Your Machine
6
Safety Introduction
9
Use
10
Introduction
10
Scope
11
Format
12
Left Side, Right Side
13
Hydraulic Schematic Codes
14
Routine Maintenance Maintenance Schedules
17
General Procedures
18
Introduction
18
Parking the Machine and Making It Safe
19
Venting the Hydraulic Pressure
20
Connecting/Disconnecting Hydraulic Hoses
21
Battery Disconnection/Connection
22
Removing and Replacing Components
23
Battery Charging System Precautions
24
Gas Hydraulic Bladder Accumulators
25
Service Consumables
28
Introduction
28
Sealing and Retaining Compounds
29
Service Tools Numerical List
31
Tool Detail Reference
33

jcb JS300 Service Manual (51 pages)

Brand: jcb | Category: Excavators | Size: 1.03 MB

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Excavators Compact Loader Power Tool Construction Equipment Drill

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Table of Contents

Table of Contents

Section B - Body and Framework

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section J - Track and Running Gear

Section K - Engine

jcb JS300 Operator's Manual (31 pages)

Table of Contents

jcb JS300 Service Manual (51 pages)

Table of Contents

jcb JS300 Service Manual (51 pages)

Table of Contents

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