OPERATOR'S MANUAL

WHEELED EXCAVATOR
JS145W, JS160W, JS20 MH

EN - 9831/5150 ISSUE 1 - 03/2018

THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

 Foreword
The Operator's Manual

You and others can be killed or seriously injured

if you operate or maintain the machine without
first studying 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.

OPERATOR'S Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
MANUAL do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.

WHEELED EXCAVATOR Machine Delivery and Installation

JS145W, JS160W, JS20 MH
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.

Following the installation you will know how to gain

maximum productivity and performance from your
new product.

Please contact your local JCB dealer if the

Installation Form (included in this manual) has not
yet been completed with you.

Your local JCB Dealer is

EN - 9831/5150 - ISSUE 1 - 03/2018

This manual contains original instructions, verified by

the manufacturer (or their authorized representative).

Copyright 2018 © JCB SERVICE

All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.

www.jcb.com

Find manuals at https://best-manuals.com

Notes:

9831/5150-1

Find manuals at https://best-manuals.com

 Table of Contents

Contents Page No.

Acronyms Glossary ....................................................................................................................................... viii

Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cross References ................................................................................................................................. 1
Safety
Safety - Yours and Others .................................................................................................................... 2
Safety Warnings .................................................................................................................................... 2
General Safety ...................................................................................................................................... 3
Clothing and Personal Protective Equipment (PPE) ............................................................................ 4

About the Product

Introduction
General .................................................................................................................................................. 5
Name and Address of the Manufacturer .............................................................................................. 5
Product Compliance .............................................................................................................................. 5
Description
General .................................................................................................................................................. 6
Intended Use ......................................................................................................................................... 6
Log Moving/Object Handling ................................................................................................................. 7
Optional Equipment and Attachments .................................................................................................. 7
Danger Zone ......................................................................................................................................... 8
Main Component Locations .................................................................................................................. 8
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 11
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 14
Safety Label Identification ................................................................................................................... 14
Operator Station
Component Locations ......................................................................................................................... 17
Interior Switches
Ignition Switch ..................................................................................................................................... 18
Multi-Purpose Switch .......................................................................................................................... 18
Cab Interior Light ................................................................................................................................ 19
Console Switches
General ................................................................................................................................................ 21
Road Lights ......................................................................................................................................... 21
Rear Fog Lights .................................................................................................................................. 21
Hazard Warning Lights ....................................................................................................................... 21
Work Lights ......................................................................................................................................... 22
Park Brake .......................................................................................................................................... 22
Beacon ................................................................................................................................................ 22
Seat Heater ......................................................................................................................................... 22
Seat Ventilation ................................................................................................................................... 22
Control Locks ...................................................................................................................................... 22

i 9831/5150-1 i

Find manuals at https://best-manuals.com

 Table of Contents

Excavator End Quickhitch ................................................................................................................... 22

Reverse Fan ....................................................................................................................................... 23
Radio Mute .......................................................................................................................................... 23
Engine Stop Switch ............................................................................................................................ 23
SCR Refresh ....................................................................................................................................... 23
Slew Lock ........................................................................................................................................... 23
Slew Smoothing .................................................................................................................................. 24
Front Lower Window Wiper ................................................................................................................ 24
Cab Raise/Lower ................................................................................................................................ 24

Operation
Introduction
General ................................................................................................................................................ 25
Operating Safety
General ................................................................................................................................................ 26
Worksite Safety ................................................................................................................................... 28
Risk Assessment ................................................................................................................................ 29
Walk-Around Inspection
General ................................................................................................................................................ 31
Entering and Leaving the Operator Station
General ................................................................................................................................................ 32
Emergency Exit ................................................................................................................................... 37
Doors
Operator Door ..................................................................................................................................... 40
Windows
Front Window ...................................................................................................................................... 42
Side Window ....................................................................................................................................... 43
Sun Visor/Sunblind
Sunblind .............................................................................................................................................. 45
Battery Isolator
General ................................................................................................................................................ 47
Before Starting the Engine
General ................................................................................................................................................ 48
Operator Seat
General ................................................................................................................................................ 49
Suspension Seat ................................................................................................................................. 49
Heated Seat Controls ......................................................................................................................... 51
Seat Ventilation Controls .................................................................................................................... 51
Seat Belt
General ................................................................................................................................................ 52
Inertia Reel Seat Belt ......................................................................................................................... 52
Static Seat Belt ................................................................................................................................... 53
Mirrors
General ................................................................................................................................................ 55
Starting the Engine
General ................................................................................................................................................ 60
Warming Up ........................................................................................................................................ 60
Immobiliser .......................................................................................................................................... 61
Stopping and Parking
General ................................................................................................................................................ 64
Preparing for Travel
General ................................................................................................................................................ 66

ii 9831/5150-1 ii

Find manuals at https://best-manuals.com

 Table of Contents

Preparing for Road Travel .................................................................................................................. 66

Preparing for Worksite Travel ............................................................................................................. 66
Beacon ................................................................................................................................................ 72
Safety Equipment
General ................................................................................................................................................ 74
Control Lock ........................................................................................................................................ 74
Drive Controls
Steering Wheel ................................................................................................................................... 76
Steering Column ................................................................................................................................. 77
Accelerator Pedal ................................................................................................................................ 77
Forward, Neutral and Reverse Switch ................................................................................................ 78
Travel Speed Selector ........................................................................................................................ 79
Service Brake Pedal ........................................................................................................................... 79
Instruments
General ................................................................................................................................................ 81
Instrument Panel ................................................................................................................................. 83
Getting the Machine Moving
General .............................................................................................................................................. 106
Slopes
General .............................................................................................................................................. 107
Driving on Slopes ............................................................................................................................. 107
Working on Slopes ........................................................................................................................... 108
Driving the Machine
Towing Other Equipment .................................................................................................................. 111
Operating Levers/Pedals
General .............................................................................................................................................. 113
Control Layouts ................................................................................................................................. 113
Excavator End Controls .................................................................................................................... 113
Dozer Blade Controls ....................................................................................................................... 137
Auxiliary Circuit Controls ................................................................................................................... 138
Lifting and Loading
General .............................................................................................................................................. 142
Load Charts ...................................................................................................................................... 142
Overload Warning System ................................................................................................................ 143
Working with the Excavator End
General .............................................................................................................................................. 145
Preparing to Use the Excavator End ................................................................................................ 145
Lifting With the Excavator End ......................................................................................................... 145
Digging .............................................................................................................................................. 146
Changing the Bucket Linkage .......................................................................................................... 152
Dipper Stroke Limiter ........................................................................................................................ 153
Working with the Dozer Blade
General .............................................................................................................................................. 156
Dozing and Grading .......................................................................................................................... 156
Scraping and Cutting ........................................................................................................................ 156
Backfilling .......................................................................................................................................... 156
Heating, Ventilating and Air-Conditioning (HVAC)
General .............................................................................................................................................. 158
Air-Conditioning Controls .................................................................................................................. 158
Power Sockets
Auxiliary Power Socket ..................................................................................................................... 161

iii 9831/5150-1 iii

Find manuals at https://best-manuals.com

 Table of Contents

Fire Extinguisher
General .............................................................................................................................................. 162
Moving a Disabled Machine
General .............................................................................................................................................. 164
Getting the Machine Unstuck ........................................................................................................... 164
Jump-Starting the Engine ................................................................................................................. 165
Retrieval ............................................................................................................................................ 166
Excavator End (Emergency Operation) ............................................................................................ 168
Lifting the Machine
General .............................................................................................................................................. 170
Transporting the Machine
General .............................................................................................................................................. 172
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................. 172
Unloading the Machine from the Transporting Vehicle/Trailer .......................................................... 177
Operating Environment
General .............................................................................................................................................. 179
Operating in Low Temperatures ....................................................................................................... 179
Operating in High Temperatures ....................................................................................................... 179
Cab Filters ......................................................................................................................................... 180
Refuelling
General .............................................................................................................................................. 181
Low Fuel Levels ................................................................................................................................ 181
Filling the Tank .................................................................................................................................. 181

Attachments
Working with Attachments
Introduction ........................................................................................................................................ 185
Attachments for your Machine .......................................................................................................... 185
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 186
Impact Protection .............................................................................................................................. 189
Direct-Mounted Attachments
General .............................................................................................................................................. 190
Quickhitch
Excavator End Quickhitch ................................................................................................................. 193
Buckets
General .............................................................................................................................................. 200
Bucket Teeth ..................................................................................................................................... 200
Rototilt
General .............................................................................................................................................. 202

Preservation and Storage

Cleaning
General .............................................................................................................................................. 203
Preparation ........................................................................................................................................ 204
Checking For Damage
General .............................................................................................................................................. 205
Storage
General .............................................................................................................................................. 206
Put into Storage ................................................................................................................................ 206
During Storage .................................................................................................................................. 206
Take out of Storage .......................................................................................................................... 207

iv 9831/5150-1 iv

Find manuals at https://best-manuals.com

 Table of Contents

Security
General .............................................................................................................................................. 208
JCB Plantguard ................................................................................................................................. 208
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 208
LiveLink ............................................................................................................................................. 208
Anti-Vandal Guards ........................................................................................................................... 208

Maintenance
Introduction
General .............................................................................................................................................. 211
Owner/Operator Support ................................................................................................................... 211
Service/Maintenance Agreements .................................................................................................... 212
Obtaining Spare Parts ...................................................................................................................... 212
Maintenance Safety
General .............................................................................................................................................. 213
Fluids and Lubricants ....................................................................................................................... 214
Maintenance Schedules
General .............................................................................................................................................. 218
How to Use the Maintenance Schedules ......................................................................................... 218
Maintenance Intervals ....................................................................................................................... 218
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 220
Functional Tests and Final Inspection .............................................................................................. 223
Maintenance Positions
General .............................................................................................................................................. 225
Maintenance Position (Excavator End Lowered) .............................................................................. 225
Service Points
General .............................................................................................................................................. 227
Access Apertures
General .............................................................................................................................................. 233
Battery Cover .................................................................................................................................... 233
Engine Compartment Cover ............................................................................................................. 233
Hydraulic Compartment Cover ......................................................................................................... 234
Tools
General .............................................................................................................................................. 236
Toolbox .............................................................................................................................................. 236
Lubrication
General .............................................................................................................................................. 237
Preparation ........................................................................................................................................ 237
Attachments
General ............................................................................................................................................. 238
Body and Framework
General ............................................................................................................................................. 239
Slew Ring Bearings .......................................................................................................................... 239
Pivot Pins .......................................................................................................................................... 240
Operator Station
General ............................................................................................................................................. 243
Operator Protective Structure ........................................................................................................... 243
Seat ................................................................................................................................................... 245
Seat Belt ........................................................................................................................................... 245
Controls ............................................................................................................................................. 246
Engine
General ............................................................................................................................................. 247

v 9831/5150-1 v

Find manuals at https://best-manuals.com

 Table of Contents

Oil ...................................................................................................................................................... 247

Drive Belt .......................................................................................................................................... 249
Air Filter
General ............................................................................................................................................. 250
Pre-Cleaner ....................................................................................................................................... 250
Dust Valve ........................................................................................................................................ 250
Fuel System
General ............................................................................................................................................. 251
Tank .................................................................................................................................................. 251
Fuel Filter .......................................................................................................................................... 252
Water Separator ............................................................................................................................... 253
Cooling System
General ............................................................................................................................................. 254
Coolant .............................................................................................................................................. 254
Cooling Pack .................................................................................................................................... 255
Brakes
Park Brake ........................................................................................................................................ 256
Service Brake ................................................................................................................................... 256
Wheels
General ............................................................................................................................................. 257
Tyres
General ............................................................................................................................................. 259
Drive Gearbox
Oil ...................................................................................................................................................... 261
Hydraulic System
General ............................................................................................................................................. 262
Services ............................................................................................................................................ 263
Oil ...................................................................................................................................................... 263
Cylinders / Rams .............................................................................................................................. 264
Electrical System
General ............................................................................................................................................. 265
Battery ............................................................................................................................................... 266
Battery Isolator ................................................................................................................................. 267
Fuses ................................................................................................................................................ 268
Relays ............................................................................................................................................... 269
Window Washer ................................................................................................................................ 269
Miscellaneous
Fire Extinguisher ............................................................................................................................... 271

Technical Data
Static Dimensions
General .............................................................................................................................................. 273
Dimensions ........................................................................................................................................ 273
Weights ............................................................................................................................................. 279
Visibility Diagrams ............................................................................................................................. 281
Performance Dimensions
Excavator End Dimensions and Performance .................................................................................. 288
Driving Performance ......................................................................................................................... 296
Attachment Dimensions
General .............................................................................................................................................. 297
Noise Emissions
General .............................................................................................................................................. 300

vi 9831/5150-1 vi

Find manuals at https://best-manuals.com

 Table of Contents

Noise Data ........................................................................................................................................ 300

Vibration Emissions
General .............................................................................................................................................. 301
Vibration Data ................................................................................................................................... 301
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 303
Fuel ................................................................................................................................................... 304
Diesel Exhaust Fluid (DEF) .............................................................................................................. 307
Coolant .............................................................................................................................................. 309
Torque Values
General .............................................................................................................................................. 311
Electrical System
General .............................................................................................................................................. 313
Bulbs ................................................................................................................................................. 313
Fuses ................................................................................................................................................. 313
Relays ............................................................................................................................................... 316
Engine
Exhaust After Treatment (EAT) ......................................................................................................... 318
Wheels and Tyres
General .............................................................................................................................................. 322
Tyre Sizes and Pressures ................................................................................................................ 322
Declaration of Conformity
General .............................................................................................................................................. 323
Data ................................................................................................................................................... 323
Warranty Information
Service Record Sheet ....................................................................................................................... 325

vii 9831/5150-1 vii

Find manuals at https://best-manuals.com

 Table of Contents

Acronyms Glossary

ARV Auxiliary Relief Valve

CESAR Construction Equipment Security and Registration
DECU Display Electronic Control Unit
DEF Diesel Exhaust Fluid
ECM Engine Control Module
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
FEAD Front End Accessory Drive
FOGS Falling Object Guard System
FOPS Falling Object Protective Structure
HRC Hydraulic Raise Cab
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LED Light Emitting Diode
PIN Product Identification Number
PPE Personal Protective Equipment
RMS Root Mean Square
ROPS Roll-Over Protective Structure
SCR Selective Catalytic Reduction
SWL Safe Working Load
TAB Triple Articulated Boom
TOPS Tip-Over Protective Structure
VGT Variable Geometry Turbocharger

viii 9831/5150-1 viii

 Introduction
About this Manual

Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
JS145W 2583731
JS160W 2584081
JS20 MH 2584181

Using the Manual

This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.

Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.

If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.

The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.

The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.

The manufacturer's policy is one of continuous improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur
between specifications of the machine and the descriptions contained in this manual.

All of the optional equipment included in this manual may not be available in all territories

Left-Hand Side, Right-Hand Side

In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.

Figure 1.
B

A
A Left B Right

Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References (Page 1).

1 9831/5150-1 1
 Introduction
Safety

Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.

In this manual and on the machine you will find warning messages, you must read and understand them. They
inform you of potential 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 any work until you are sure that you and those around you will be safe.

If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.

Remember:

• Be careful
• Be alert
• Be safe.

Safety Warnings
In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are
given below.

The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.

The signal word 'WARNING' indicates a hazardous situation 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 symbol (shown) also helps to identify important safety messages in this manual. When
you see this symbol your safety is involved, carefully read the message that follows.

Figure 2. The safety alert system symbol

2 9831/5150-1 2
 Introduction
Safety

General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. Ensure that
you receive the correct training before operating any machinery. Failing to do so will result in incorrect operation
of the machine and you will be putting yourself and others at risk. In some markets, and for work on certain
jobsites, you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements – it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be 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.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
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.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.

3 9831/5150-1 3
 Introduction
Safety

Clothing and Personal Protective Equipment (PPE)

Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.

4 9831/5150-1 4
 About the Product
Introduction

About the Product

Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.

Name and Address of the Manufacturer

JCB Heavy Products Limited, Lakeside Works, Rocester, Staffordshire, United Kingdom, ST14 5JP.

Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.

For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.

Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.

Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.

JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.

5 9831/5150-1 5
 About the Product
Description

Description
General
For: JS145W [T4F], JS160W [T4F] ............................................................................................ Page 6
For: JS20 MH [T4F] ................................................................................................................... Page 6

(For: JS145W [T4F], JS160W [T4F])

The JCB Wheeled Excavator is a self propelled machine with a wheeled undercarriage and a revolving upper
structure which has a boom, dipper, bucket and slew mechanism.

The excavator is mainly used to dig below ground level with bucket motions towards the machine. The upper
structure can slew 360 ° and discharge material when the wheeled undercarriage is stationary.

Waste Applications
The machine is mainly used to lift materials or scrap with an attachment. The upper structure can slew 360°
and discharge the materials or scrap when the wheeled undercarriage is stationary.

(For: JS20 MH [T4F])

The machine is a self propelled with a wheeled undercarriage and a revolving upper structure which has a
boom, dipper, grab and slew mechanism.

The machine is mainly used to lift materials or scrap with an attachment. The upper structure can slew 360 °
and discharge the materials or scrap when the wheeled undercarriage is stationary.

Intended Use
For: JS145W [T4F], JS160W [T4F] ............................................................................................ Page 6
For: JS20 MH [T4F] ................................................................................................................... Page 7

(For: JS145W [T4F], JS160W [T4F])

The machine is intended to be used in normal conditions for the applications and in the environmental conditions
as described in this manual.

When used normally with a bucket fitted to the machine the work cycle consists of, digging, elevating, slewing
and the discharging of material without movement of the undercarriage.

Applications include earthmoving, road construction, building and construction, landscaping and similar
applications.

An excavator can also be used for object handling if it is suitably equipped with relevant parts and systems.
Refer to: Lifting and Loading (Page 142).

The machine must not be used in the following scenarios because of the risk of overturning; used for forestry,
used with attachments of unknown weight, used on surfaces of unknown stability. This list is not exhaustive.

If the machine is to be used in applications where there is a high silica concentration, risk due to materials
containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal
Protective Equipment) may be required.

The machine should not be operated by any person who does not have an appropriate level of qualification,
training or experience of use of this type of machine.

Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with
regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for
support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable
for the application and environment.

6 9831/5150-1 6
 About the Product
Description

Waste Applications
The boom/arm should not be operated so as to punch the waste in order to compact it. To compact waste
the boom/arm can be used to exert pressure on the material, lowering the attachment onto the waste and
continuing to lower the boom so as to exert the weight of the machine on the material being compacted, but
without causing the stabilisers to be lifted clear of the ground. Excessively raising the machine above ground,
punching the waste, lifting the stabilisers clear of the ground during compacting and any other actions that
impart significant shock loads into the machine structure are outside of the intended use of the machine and
can have a damaging effect on the machine structure and hydraulic system.

The correct position of the stabiliser legs in waste compaction application is with the legs lowered so that the
wheels are lifted just clear of the ground, taking the weight off the wheels (not fully lowered so as to substantially
lift the machine).

The dozer blade must be raised clear off the ground where applicable during the correct compaction procedures
as outlined above.

(For: JS20 MH [T4F])

The machine is intended to be used in normal conditions for the applications described in this manual. If the
machine is used for other applications or in dangerous environments, for example in a flammable atmosphere
or in areas with dust containing asbestos, special safety regulations must be obeyed and the machine must
be equipped for use in these environments.

The machine is primarily designed for materials or scrap handling with an attachment, without movement of
the undercarriage during the work cycle. A normal work cycle comprises handling, elevating, slewing and
discharging of material.

The machine can be used for object or material/scrap handling/transportation if it meets the lifting regulations.
Refer to: Lifting and Loading (Page 142).

Waste Applications
The boom/arm should not be operated so as to punch the waste in order to compact it. To compact waste
the boom/arm can be used to exert pressure on the material, lowering the attachment onto the waste and
continuing to lower the boom so as to exert the weight of the machine on the material being compacted, but
without causing the stabilisers to be lifted clear of the ground. Excessively raising the machine above ground,
punching the waste, lifting the stabilisers clear of the ground during compacting and any other actions that
impart significant shock loads into the machine structure are outside of the intended use of the machine and
can have a damaging effect on the machine structure and hydraulic system.

The correct position of the stabiliser legs in waste compaction application is with the legs lowered so that the
wheels are lifted just clear of the ground, taking the weight off the wheels (not fully lowered so as to substantially
lift the machine).

Optional dozerblade on JS200 Wastemaster when fitted must be raised clear off the ground during the correct
compaction procedures as outlined above.

Log Moving/Object Handling

Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause
serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.

Optional Equipment and Attachments

A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB
approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list
of approved attachments available.

7 9831/5150-1 7
 About the Product
Description

Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. The danger zone includes the area in immediate proximity to any hazardous moving parts,
areas into which working equipment and attachments can be moved to quickly, the machine normal stopping
distances and also areas into which the machine can quickly turn under normal conditions of use. Depending
on the application at the time, the danger zone could also include the area into which debris, from use of an
attachment or working tool, could be projected and any area into which debris could fall from the machine.
During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone
could be injured.

Before you do a maintenance task, make the product safe.

Main Component Locations

For: JS145W [T4F], JS160W [T4F] ............................................................................................ Page 8
For: JS20 MH [T4F] ................................................................................................................... Page 9

(For: JS145W [T4F], JS160W [T4F])

Figure 3.
J
H
G
K
F

D C E B 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

8 9831/5150-1 8
 About the Product
Description

(For: JS20 MH [T4F])

Figure 4.

F
D

G H
C

A
J

F
D

G H
C

A Attachment ram B Dipper

C Dipper ram D Boom
E Operators cab F Cab ram
G Reversing fan control panel H Counterweight
J Stabilisers

9 9831/5150-1 9
 About the Product
Product and Component Identification

Product and Component Identification

Machine

Your machine has an identification plate. The PIN (Product Identification Number), weight, engine power, year
of manufacture and serial number of the machine are shown on the identification plate.

The machine serial number is also inscribed at the baseplate of the rear frame.

Figure 5.

A Identification plate (location) B Serial number (inscribed)

Figure 6.

The machine model and build specification are indicated by the PIN. The PIN has 17 digits and must be read
from left to right.

Table 1. Typical PIN

JCB JW14C C 01786864

Table 2. Explanation of the PIN

Digit Description
1 to 3 World manufacturer identification. For
example, JCB = UK Build.
4 to 8 Machine type and model. For example,
JW14C = JS145 Wheeled.
9 Random check letter. The check let-
ter is used to verify the authenticity of a
machine's PIN.
10 to 17 Machine serial number (01786864).

10 9831/5150-1 10
 About the Product
Product and Component Identification

Engine

The engine data labels are attached to the cylinder block as shown.

Figure 7.
C

A D

B
D

A Engine data label - rocker cover B Engine data label - tread plate
C Engine identification number D Stamp

The data label includes the engine identification number.

Table 3. Example of the engine identification number

SJ 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18

Table 4.
Digit 1-2 Engine Type
SJ 4.4 L turbocharged and aftercooled electronic common rail fuel injection (tier 4F)
> 55 kW
SL 4.4 L turbocharged and aftercooled electronic common rail fuel injection (tier 4F)
< 55 kW
DJ 4.8 L turbocharged and aftercooled electronic common rail fuel injection (tier 4F)
> 55 kW

Table 5. Explanation of the engine identification number

Digit Explanation
3-10 Engine part number
11 Country of manufacture. U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture

The country of manufacturer, engine serial number and year of manufacture of the engine are also stamped
on the cylinder block. Refer to Figure 7.

Operator Protective Structure

WARNING Machines with a ROPS, FOPS,FOGS or TOPS are equipped with a seat belt. The ROPS,
FOPS,FOGS or TOPS is designed to give you protection in an accident. If you do not wear the seat belt you

11 9831/5150-1 11
 About the Product
Product and Component Identification

could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten
the seat belt before starting the engine.
WARNING Modified and wrongly repaired ROPS, TOPS and FOGS are dangerous. Do not modify the
TOPS. Do not attempt to repair the ROPS, TOPS and FOGS. If the ROPS, TOPS and FOGS has been in
an accident, do not use the machine until the structure has been examined and repaired. This must be done
by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in
death or injury to the operator.

FOGS Data Plate

WARNING Do not use the machine if the falling objects protection level provided by the structure is not
sufficient for the application. Falling objects can cause serious injury.

If the machine is used in any application where there is a risk of falling objects then a FOGS (Falling Object
Guard System) must be installed. For further information, contact your JCB dealer.

The FOGS has a data plate attached. The data plate indicates what level of protection the structure provides.

There are two levels of FOGS:

• Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small
concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and
other construction site services.
• Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for
machines involved in site clearing, overhead demolition or forestry.
Figure 8.

The cab mounted FOGS available for the JS excavator range are tested to ISO 10262 level 2 and comply
with EN 13627:2000.

The frame mounted FOGS available for the JS excavator range are tested to ISO 3449 level 2 and comply
with EN 13627:2000.

ROPS Data Plate

WARNING Your machine may be installed with a Roll-Over Protective Structure (ROPS) indicating that the
purchaser specified the machine for use in applications where there is risk of roll-over. ROPS is a device
to protect the operator in the event of roll-over. Any damage or modification to the structure may invalidate
the ROPS certification. If damage has occurred then an authorised JCB dealer should be consulted.

An excavator with a ROPS (Roll-Over Protective Structure) can be identified by referring to the identification
plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need
for an excavator with a ROPS.

TOPS Data Plate

An excavator with a TOPS (Tip-Over Protective Structure) can be identified by referring to the cab identification
plate. Work place (work site, job site) risk assessment should facilitate the machine selection and the need
for an excavator with a TOPS.

12 9831/5150-1 12
 About the Product
Product and Component Identification

Figure 9.

13 9831/5150-1 13
 About the Product
Safety Labels

Safety Labels
General
WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not
obey the safety instructions shown.

The safety labels are strategically placed around the machine to remind you of possible hazards.

If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-
stretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard
shown on the safety label, then refer to Safety Label Identification.

Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the
replacement parts include the safety labels where necessary. Each safety label has a part number printed on
it, use this number to order a new safety label from your JCB dealer.

Safety Label Identification

Figure 10.

A B C D

332/ J2896

J F

14 9831/5150-1 14
 About the Product
Safety Labels

Figure 11.

M L
M

332/ J9693

Table 6. Safety Labels

Item Part No. Description Qty.
A 332/J2896 (Combination label) Warning. The coolant is under pressure. Risk of 1
severing of hands/fingers in the rotating parts. Hot surfaces. Remove the
ignition key and refer to the operator's manual and the service manual.
B 817/70005 Hot fluid under pressure. Do not touch, consult operator's manual. 1
C 332/P4679 Warning. Severing of hands and fingers. Keep clear of/do not reach into 1
rotating parts. Read the Service Manual.
D 817/70024 Warning. Do not use as a step. 1
E 332/F5860 Warning. Hot fluid under pressure. Read the Operator's Manual. 1
F 817/70003 Crushing/shearing of hands. Do not touch. 1
G 334/K3643 Unexpected machine movement due to accidental contact with the 1
controls when the hydraulics are not isolated. Before exiting the cab leave
the machine in a parked state and remove the ignition key. Refer to
Stopping and Parking section in the operator’s manual.
H 817/18541 Read the operator's manual before you operate the machine. 1
J 817/19470 The arm or bucket may move, keep clear. 1
K 332/J9693 (Combination label) The bucket can foul the boom when dipper is swinging 1
inwards. Maintain the clearance between the bucket and boom. Danger
of collision, maintain the clearance between the bucket and cab. Risk of

15 9831/5150-1 15
 About the Product
Safety Labels

Item Part No. Description Qty.

tripping, raise the control lock lever before you exit the machine. Risk of
injury by crushing, do not lean out of the window. Risk of electrocution,
maintain the minimum clearance recommended by your local electricity
supplier.
L 817/70027 Warning. Crushing of whole body. Keep a safe distance. 1
M 817/70001 Falling hazard. Keep a safe distance from the edge. 1
N 817/18532 Warning. Pressure hazard. Stop the engine, remove the ignition key and 1
release the hydraulic pressure before you start maintenance work. Refer
to Maintenance Section in the operator's manual.

16 9831/5150-1 16
 About the Product
Operator Station

Operator Station
Component Locations
Figure 12.

E
G

F
B

P
D
Q

R
H

J
U
K
S
L

T M

N
N
A TAB (Triple Articulated Boom) pedal, Refer to: B Auxiliary pedal, Refer to: Auxiliary Circuit
Excavator End Controls (Page 113). Controls (Page 138).
C Service brake pedalRefer to: Service Brake D Travel pedalRefer to: Accelerator Pedal
Pedal (Page 79). (Page 77).
E Steering wheel, Refer to: Steering Wheel F Multi purpose steering column switch, Refer to:
(Page 76). Steering Column (Page 77).
G DECU (Display Electronic Control Unit) Refer to: H Right joystick, Refer to: Excavator End Controls
Instrument Panel (Page 83). (Page 113).
J Machine power band controller, Refer to: K Ignition switch, Refer to: Ignition Switch
General (Page 81). (Page 18).
L Dozer lever, Refer to: Dozer Blade Controls M Right switch console, Refer to: General
(Page 137). (Page 21).
N 12 V auxiliary power socket, Refer to: Auxiliary P Left joystick, Refer to: Excavator End Controls
Power Socket (Page 161). (Page 113).
Q Seat, Refer to: General (Page 49). R Controls isolation lever, Refer to: Control Lock
(Page 74).
S Left switch console, Refer to: General T Door lever, Refer to: Operator Door
(Page 21). (Page 40).
U Wheeled switch panelRefer to: General
(Page 81).

17 9831/5150-1 17
 About the Product
Interior Switches

Interior Switches
Ignition Switch
The ignition key operates the four-position ignition switch. The ignition key can only be inserted or removed
in position 0.

If the engine fails to start, the ignition key must be returned to position 0 before the starter motor is re-engaged.

Do not operate the starter motor for more than 20 s without the engine firing. If the engine fires but does not
fully start, let the starter motor cool for at least 2 min between starts.

Figure 13.

B
A Ignition switch B Ignition key

Table 7. Switch Positions

Position Function
0 Off/Stop the Engine: Turn the ignition key to this position to stop the engine.
Make sure the controls are in neutral and the excavator and dozer are lowered
before you stop the engine.
I On: Turn the ignition key to this position to connect the battery to all of the elec-
trical circuits. The ignition key will return to this position when it is released from
position II or position III.
II This position is not used.
III Start: Turn the ignition key to this position to operate the starter motor and turn
the engine. The ignition switch has an inhibitor to stop the ignition switch being
turned on when the engine is running. There may be a delay of up to 1 s be-
tween switch operation and engine cranking.

Multi-Purpose Switch
Right Turn
Pull the lever towards you to indicate a right turn. Switch the indicators off when you have completed the turn.
Functions only with the starter switch at ON, cancels automatically when steering wheel centres.

Left Turn
Push the lever away from you to indicate a left turn. Switch the indicators off when you have completed the
turn. Functions only with the starter switch at ON cancels automatically when steering wheel centres.

A buzzer will sound when the indicators are on as a reminder.

Front Window Wiper

Rotate the three position barrel to operate the front window wipers. Fully counterclockwise is off, the middle
position is intermittent wipe, and the fully clockwise position is continuous wipe.

The delay time of the intermittent wiper can be adjusted using the DECU (Display Electronic Control Unit)

18 9831/5150-1 18
 About the Product
Interior Switches

The wipers will self-park when switched off. Functions only with the starter switch at on.

Front Windscreen Washer

Push the sleeve towards the steering wheel to operate the front window washer. Functions only with the starter
switch at on.

Main Beam
Lift the lever to switch on the main beam. Lift the lever once more to re-select dipped beam. Functions only with
sidelights and headlights selected to on. Lifting the lever with main beam switched off will flash the main beam.

Horn
Press to sound the horn. Functions only with the starter switch at on.

Figure 14.
B
E

C F D

A
A Right turn B Left turn
C Front windscreen wiper D Horn
E Main beam F Front windscreen washer

Cab Interior Light

Press either end of the light unit to turn on the cab interior light.

Press the other end of the light unit to turn off the cab interior light.

When the cab interior light is in the centre position, it will turn on automatically when the cab door is opened
and turn off when the door is closed.

A timer will switch off the cab interior light if the cab door is left open for prolonged periods.

Make sure the cab interior light is turned off when you intend to leave the machine for a long period of time.

Figure 15.

A
A Cab interior light

19 9831/5150-1 19
This as a preview PDF file from best-manuals.com

Download full PDF manual at best-manuals.com