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 01 - Machine

 03 - Safety

 18 - Operating Safety

01 - 8

9813/2650-3

01 - 8

18 - Operating Safety
Introduction

Training

Make sure that you have had adequate training and

that you are confident in your ability to operate the

machine safely before you use it. Practice using the

machine and its attachments until you are completely

familiar  with  the  controls  and  what  they  do.  With

a  careful,  well  trained  and  experienced  operator,

your machine is a safe and efficient machine. With

an  inexperienced  or  careless  operator,  it  can  be

dangerous. Do not put your life, or the lives of others,

at risk by using the machine irresponsibly. Before you

start to work, tell your colleagues what you will be

doing and where you will be working. On a busy site,

use a signalman.
Before doing any job not covered in this manual, find

out the correct procedure. Your local JCB distributor

will be glad to advise you.

Fuel

Fuel is flammable, keep naked flames away from the

fuel  system.  Stop  the  engine  immediately  if  a  fuel

leak is suspected. Do not smoke while refuelling or

working on the fuel system. Do not refuel with the

engine  running.  Completely  wipe  off  any  spilt  fuel

which could cause a fire. There could be a fire and

injury if you do not follow these precautions.

Machine Condition

A defective machine can injure you or others. Do not

operate a machine which is defective or has missing

parts. Make sure the maintenance procedures in this

manual are completed before using the machine.

Machine Limits

Operating the machine beyond its design limits can

damage  the  machine,  it  can  also  be  dangerous.

Do  not  operate  the  machine  outside  its  limits.  Do

not  try  to  upgrade  the  machine  performance  with

unapproved modifications.

Engine/Steering Failure

If the engine or steering fails, stop the machine as

quickly as possible. Do not operate the machine until

the fault has been corrected.

Exhaust Gases

Machine exhaust gases can harm and possibly 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  machine  or  if

piled material collapses onto it. Check for potholes

and hidden debris, logs, ironwork etc. Any of these

could  cause  you  to  lose  control  of  your  machine.

Check for utilities such as electric cables (overhead

and  underground),  gas  and  water  pipes  etc.  Mark

the positions of the underground cables and pipes.

Make sure that you have enough clearance beneath

overhead cables and structures.

Communications

Bad  communications  can  cause  accidents.  Keep

people  around  you  informed  of  what  you  will  be

doing.  If  you  will  be  working  with  other  people,

make sure any hand signals that may be used are

understood by everybody. Worksites can be noisy, do

not rely on spoken commands.

Parking

An incorrectly parked machine can move without an

operator.  Follow  the  instructions  in  the  Operator's

Manual to park the machine correctly.

Banks and Trenches

Banked material and trenches can collapse. Do not

work or drive too close to banks and trenches where

there is danger of collapse.

Safety Barriers

Unguarded  machines  in  public  places  can  be

dangerous. In public places, or where your visibility

is reduced, place barriers around the work area to

keep people away.

Sparks

Explosions and fire can be caused by sparks from

the exhaust or the electrical system. Do not use the

machine in closed areas where there is flammable

material, vapour or dust.

Hazardous Atmospheres

This  machine  is  designed  for  use  in  normal  out

door  atmospheric  conditions.  It  must  not  be  used

in  an  enclosed  area  without  adequate  ventilation.

Do  not  use  the  machine  in  a  potentially  explosive

atmosphere, i.e. combustible vapours, gas or dust,

without first consulting your JCB dealer.

Regulations

Obey all laws, worksite and local regulations which

affect you and your machine.

Summary of Contents for JS145W

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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