jcb JS145W, Service Manual

Page 1: ...g 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 Operato...

Page 2: ...9813 2650 3 Notes Find manuals at https best manuals com ...

Page 3: ...1 JS145W JS160W JS175W EN 9813 2650 SERVICE MANUAL Volume 2 JS145W JS160W JS175W EN 9813 2650 SERVICE MANUAL Volume 3 JS145W JS160W JS175W EN 9813 2650 SERVICE MANUAL Volume 4 JS145W JS160W JS175W EN 9813 2650 Find manuals at https best manuals com ...

Page 4: ...Notes 9813 2650 3 Find manuals at https best manuals com ...

Page 5: ...ral 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 01 06 About this Manual 01 06 06 Using the Manual 01 15 01 09 Description 01 09 12 Main Component Locations 01 17 01 09 15 Service Point Locations 01 18 Find manuals at https best manuals com ...

Page 6: ...9813 2650 3 2016 08 24 Acronyms Glossary PIL Parts Identification List 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 2650 3 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: ...ware 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 Switch...

Page 12: ...eer Hydraulic 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 r...

Page 13: ...idence of decomposition 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 ...

Page 14: ...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 machine or if pile...

Page 15: ... 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 others can be killed or seriou...

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: ...elease the hydraulic pressure and the tank 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 JS20 MH JS200 Wastemaster Machines 1 Park the machine on solid level ground with the upper structure parallel to the undercarriage 2 Lower the lift arm so the dipper is flat on the ground Figure 3 A A Lift arm lowered with the dippe...

Page 19: ...01 Machine 06 About this Manual 01 13 9813 2650 3 01 13 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 15 ...

Page 20: ...Notes 01 14 9813 2650 3 01 14 ...

Page 21: ...ery Isolation Switch 33 09 00 Power Distribution including fuses and relays 33 00 50 Schematic Circuit Machine Variants Where information is different depending on machine variant the applicable 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 Diagnostics Information in thi...

Page 22: ...01 Machine 09 Description 01 16 9813 2650 3 01 16 09 Description Contents Page No 01 09 12 Main Component Locations 01 17 01 09 15 Service Point Locations 01 18 ...

Page 23: ...ions 01 17 9813 2650 3 01 17 12 Main Component Locations Component Identification Figure 4 A H F G B C E D K J L A Bucket B Bucket link C Bucket ram D Dipper E Dipper link F Dipper ram G Boom H Boom ram J Operators cab K Counterweight L Undercarriage ...

Page 24: ...cture Figure 5 A B C E F G D H J K L M Q N P A Engine oil dipstick B Radiator cap and expansion bottle C Engine oil filler cap D Diesel level indicator E Fuel filler cap F Cover suction strainer G Hydraulic oil filler cap cover return filter H Hydraulic tank breather J Drain plug slew gearbox K Filler port slew gearbox if installed L Dipstick slew gearbox M Filter breaker in line JS110 190 N Cushi...

Page 25: ...rallel to the undercarriage 2 Make the machine safe 3 Hold the handrail with both hands then use the step between the top and bottom steps to climb onto the top of the undercarriage Keep three points of contact with the machine at all times 4 Keep hold of the handrail and use the steps on the toolbox to climb up to the top of the upper structure Keep two points of contact with the machine at all t...

Page 26: ...01 Machine 09 Description 15 Service Point Locations 01 20 9813 2650 3 01 20 Battery Compartment Figure 9 A B C D E A Air intake B Radiator s C Batteries D Window washer fluid bottle E Battery isolator ...

Page 27: ...ompartment Figure 10 A B C D F E G J H A Main fuel filter B Hydraulic oil level indicator C Primary fuel filter D Engine fuel filter E Steering line filter JS145W JS160W JS175W F Servo filter element G In line drain filter H Plexus filter element JS200 220 J Plexus filter element JS110 190 ...

Page 28: ...01 Machine 09 Description 15 Service Point Locations 01 22 9813 2650 3 01 22 Undercarriage Figure 11 A B B A A Tyre B Wheel nut ...

Page 29: ...03 Attachments and Options Contents Page No Acronyms Glossary 03 2 03 00 General 03 00 00 General 03 3 03 10 Excavator Arm Quickhitch 03 10 06 Hydraulic Quickhitch 03 7 03 27 Bucket 03 27 00 General 03 13 03 27 90 Teeth 03 15 ...

Page 30: ...9813 2650 3 2016 03 22 Acronyms Glossary CAN Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit LED Light Emitting Diode ...

Page 31: ...03 Attachments and Options 00 General 03 1 9813 2650 3 03 1 00 General Contents Page No 03 00 00 General 03 3 ...

Page 32: ...Notes 03 2 9813 2650 3 03 2 ...

Page 33: ...ients 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 create safety...

Page 34: ...load 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 platform is h...

Page 35: ...03 Attachments and Options 10 Excavator Arm Quickhitch 03 5 9813 2650 3 03 5 10 Excavator Arm Quickhitch Contents Page No 03 10 06 Hydraulic Quickhitch 03 7 ...

Page 36: ...Notes 03 6 9813 2650 3 03 6 ...

Page 37: ... 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 12 Typical hydraulic quickhitch installation C B D A A Hydr...

Page 38: ...s pressed the switch by mistake the switch can be selected in the opposite direction and an input is sent to pin 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 posit...

Page 39: ...03 Attachments and Options 10 Excavator Arm Quickhitch 06 Hydraulic Quickhitch 03 9 9813 2650 3 03 9 released before the procedure is complete the unlock procedure must be repeated from the start ...

Page 40: ... 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 alignment C158 S...

Page 41: ...4 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 42: ...03 Attachments and Options 27 Bucket 03 12 9813 2650 3 03 12 27 Bucket Contents Page No 03 27 00 General 03 13 03 27 90 Teeth 03 15 ...

Page 43: ...installed on many different types of excavating machines The bucket can be directly mounted on to an excavator arm assembly or mounted to the excavator arm via a quickhitch assembly There are a vast amount and size of buckets used for numerous applications Excavator buckets are made of solid steel and generally have teeth protruding from the cutting edge ...

Page 44: ...over WARNING The bucket selected must be the correct width to suit the hole trench to be excavated However if the hole width demands a larger bucket consideration must be given to the density weight of the material to be moved affecting the stability of the machine especially if working on a slope If there is danger of the machine s stability being compromised then select a smaller bucket or repos...

Page 45: ...15 90 Teeth Introduction 03 15 Remove and Install 03 16 Introduction Excavator buckets generally have teeth protruding from the cutting edge to disrupt hard material and avoid wear and tear of the bucket Bucket teeth are available in a wide range of sizes and profiles ...

Page 46: ... to PIL 01 03 2 Put the bucket flat on level ground 3 Stop the engine 4 Remove the ignition key 5 Discharge the hydraulic pressure Refer to PIL 30 00 6 Remove the nut and bolt 7 Remove the relevant tooth Figure 18 A B A Tooth B Nut and bolt Installation 1 Put the tooth in position 2 Install the nuts and bolts to secure the tooth in position ...

Page 47: ...06 15 00 General 06 9 06 15 03 Boom 06 11 06 15 06 Dipper 06 15 06 15 15 Tipping Linkage 06 18 06 24 Slew Ring 06 24 03 Bearing 06 23 06 30 Pivot Pins 06 30 00 General 06 29 06 63 Identification Label 06 63 00 General 06 33 06 63 06 Engine 06 34 06 63 09 Axle 06 35 06 63 12 Gearbox 06 36 06 63 15 Operator Protective Structure 06 37 06 66 Tools 06 66 00 General 06 41 06 66 03 Toolbox 06 42 06 75 Fi...

Page 48: ...9813 2650 3 2016 08 24 Acronyms Glossary DTI Dial Test Indicator FOGS Falling Object Guard System LH Left Hand RH Right Hand ROPS Roll Over Protective Structure TOPS Tip Over Protective Structure ...

Page 49: ... Body and Framework 06 Access Cover 06 1 9813 2650 3 06 1 06 Access Cover Contents Page No 06 06 00 General 06 3 06 06 03 Battery 06 4 06 06 06 Engine Compartment 06 5 06 06 09 Hydraulic Compartment 06 6 ...

Page 50: ...Notes 06 2 9813 2650 3 06 2 ...

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