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 01 - Machine

 03 - Safety

 12 - Maintenance Safety

01 - 6

9813/2650-3

01 - 6

12 - Maintenance Safety
Introduction

Raised Machine

Never  position  yourself  or  any  part  of  your  body

under  a  raised  machine  which  is  not  correctly

supported. If the machine moves unexpectedly you

could become trapped and suffer serious injury or be

killed.

Air Conditioning Maintenance

The air conditioning system is a closed loop system

and contains pressurised refrigerant. No part of the

system  should  be  disconnected  until  the  system

has  been  discharged  by  a  refrigeration  engineer

or  a  suitably  trained  person.  You  can  be  severely

frostbitten or injured by escaping refrigerant.

Compressed Air

Compressed  air  is  dangerous.  Wear  personal

protective equipment. Never point a compressed air

jet at yourself or others.

Springs

Always  wear  personal  protective  equipment  when

dismantling  assemblies  containing  components

under pressure from springs. This will protect against

eye injury from components accidentally flying out.

Metal Splinters

You  can  be  injured  by  flying  metal  splinters  when

driving metal pins in or out. Use a soft faced hammer

or  copper  drift  to  remove  and  install  metal  pins.

Always wear personal protective equipment.

Communications

Bad  communications  can  cause  accidents.  If  two

or more people are working on the machine, make

sure  each  is  aware  of  what  the  others  are  doing.

Before starting the engine make sure the others are

clear of the danger areas. Examples of danger areas

are: the rotating blades and belt on the engine, the

attachments and linkages, and anywhere beneath or

behind the machine. People can be killed or injured

if these precautions are not taken.

Repairs

If  your  machine  does  not  function  correctly  in

any  way,  get  it  repaired  straight  away.  Neglect  of

necessary repairs could result in an accident or affect

your  health.  Do  not  try  to  do  repairs  or  any  other

type of maintenance work you do not understand. To

avoid injury and/or damage get the work done by a

specialist engineer.

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  rotted  'O'  rings,  seals

and  gaskets  can  cause  leakages  and  possible

accidents.  Renew  whenever  disturbed  unless

otherwise instructed. Do not use Triochloroethane or

paint thinners near 'O' rings and seals.

Arc Welding

To  prevent  the  possibility  of  damage  to  electronic

components,  disconnect  the  battery  and  the

alternator  before  arc-welding  on  the  machine  or

attached implements.
If the machine is equipped with sensitive electrical

equipment,  i.e.  amplifier  drivers,  electronic  control

units (ECUs), monitor displays, etc., then disconnect

them  before  welding.  Failure  to  disconnect  the

sensitive  electrical  equipment  could  result  in

irreparable damage to these components.
Parts of the machine are made from cast iron, welds

on cast iron can weaken the structure and break. Do

not weld cast iron. Do not connect the welder cable

or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to

the same component that is being welded to avoid

damage to pivot pins, bearings and bushes. Attach

the welder earth (ground) cable a distance from the

part being welded no more than 0.6m.

Counterweights

Your machine may be installed with counterweights.

They are extremely heavy. Do not attempt to remove

them.

Accumulators

The accumulators contain hydraulic fluid and gas at

high  pressure.  Prior  to  any  work  being  carried  out

on systems incorporating accumulators, the system

pressure  must  be  discharged  by  a  JCB  dealer,  as

the sudden release of the hydraulic fluid or gas may

cause injury.

Hot Components

Touching hot surfaces can burn skin. The engine and

machine components will be hot after the unit has

been running. Allow the engine and components to

cool before servicing the unit.

Soft Ground

A  machine  can  sink  into  soft  ground.  Never  work

under a machine on soft ground.

Содержание JS145W

Страница 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...

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

Страница 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 ...

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

Страница 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 ...

Страница 6: ...9813 2650 3 2016 08 24 Acronyms Glossary PIL Parts Identification List Find manuals at https best manuals com ...

Страница 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 ...

Страница 8: ...Notes 01 2 9813 2650 3 01 2 Find manuals at https best manuals com ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

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

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

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