jcb JS20 MH Service Manual
jcb JS20 MH Service Manual

jcb JS20 MH Service Manual

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SERVICE MANUAL
WHEELED EXCAVATOR
JS145W, JS160W, JS20 MH
EN - 9813/9550 - ISSUE 1 - 02/2018
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
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.
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
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Table of Contents
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what would stop the cab going up in the air on jcb js20mh

Summary of Contents for jcb JS20 MH

  • Page 1 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/9550-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 JS145W, JS160W, JS20 MH JS145W, JS160W, JS20 MH EN 9813/9550 EN 9813/9550 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 JS145W, JS160W, JS20 MH JS145W, JS160W, JS20 MH EN 9813/9550...
  • Page 4 Notes: 9813/9550-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - 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 ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Diesel Exhaust Fluid Parts Identification List 9813/9550-1 2018-02-21 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - 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 ......................
  • Page 8 Notes: 01 - 2 9813/9550-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    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.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction 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.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    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 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.
  • Page 19: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-15 01-06-06 Using the Manual ......................01-16 01 - 13 9813/9550-1 01 - 13...
  • Page 20 Notes: 01 - 14 9813/9550-1 01 - 14...
  • Page 21: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: JS145W 2583731 JS160W 2584081...
  • Page 22: Using The Manual

    Introduction Information in this manual conforms to a standard Information within each PIL reference is included JCB service manual format. The format uses section under a set of standard headings such as headings taken from a PIL (Parts Identification Introduction, Health and Safety, Technical Data and List).
  • Page 23: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-19 01-09-15 Service Point Locations ....................01-21 01 - 17 9813/9550-1 01 - 17...
  • Page 24 Notes: 01 - 18 9813/9550-1 01 - 18...
  • Page 25: Main Component Locations

    12 - Main Component Locations 12 - Main Component Locations Component Identification For: JS145W [T4F], JS160W [T4F], Standard Cab ......Page 01-19 For: JS20 MH [T4F], High Rise Cab (HRC) ........... Page 01-20 (For: JS145W [T4F], JS160W [T4F], Standard Cab) Figure 4. A Bucket...
  • Page 26 01 - Machine 09 - Description 12 - Main Component Locations (For: JS20 MH [T4F], High Rise Cab (HRC)) Figure 5. A Attachment ram B Dipper C Dipper ram D Boom E Operators cab F Cab ram G Reversing fan control panel...
  • Page 27: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction CAUTION Make sure the steps, handrails, and climbing onto the machine. Always face the your footwear soles are clean and dry before machine when climbing on and off it. Upper Structure Figure 6.
  • Page 28 01 - Machine 09 - Description 15 - Service Point Locations Access to the Upper Structure Figure 9. Figure 7. 1. Park the machine on solid, level ground with the upper structure parallel to the undercarriage. Figure 8. 2. Make the machine safe. 3.
  • Page 29: Battery Compartment

    01 - Machine 09 - Description 15 - Service Point Locations Battery Compartment Figure 10. A Air intake B Radiator(s) C Batteries D Window washer fluid bottle E Battery isolator 01 - 23 9813/9550-1 01 - 23...
  • Page 30: Hydraulic Compartment

    01 - Machine 09 - Description 15 - Service Point Locations Hydraulic Compartment Figure 11. A Hydraulic oil level indicator B Primary fuel filter C Engine fuel filter D Fuel tap 01 - 24 9813/9550-1 01 - 24...
  • Page 31 01 - Machine 09 - Description 15 - Service Point Locations Undercarriage Figure 12. A Tyre B Wheel nut 01 - 25 9813/9550-1 01 - 25...
  • Page 32 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-27 01 - 26 9813/9550-1 01 - 26...
  • Page 33 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-27 or other chemicals, you must adhere to Preparation ............ 01-28 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 34 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 35 03 - Attachments, Couplings and Load Handling Contents Page No. Acronyms Glossary ............................ 03-2 03-00 Attachments 03-00-00 General ..........................03-3 03-10 Excavator End Quickhitch 03-10-06 Hydraulic Quickhitch ......................03-7 03-27 Bucket 03-27-00 General ........................... 03-13 03-27-90 Teeth ..........................03-16 9813/9550-1 2017-11-23...
  • Page 36: Acronyms Glossary

    Acronyms Glossary Controller Area Network DECU Display Electronic Control Unit HECU Hydraulics Electronic Control Unit Light Emitting Diode 9813/9550-1 2017-11-23...
  • Page 37: Attachments

    03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/9550-1 03 - 1...
  • Page 38 Notes: 03 - 2 9813/9550-1 03 - 2...
  • Page 39: General

    03-3 A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use Check (Condition) ..........03-4 with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 40: Health And Safety

    Check (Condition) Attachments Purpose Tests Lifting Use only the JCB approved attachments that are Equipment specified for your machine. Operating with non- specified attachments can overload the machine, All lifting equipment (for example forks, lifting hooks causing possible damage and machine instability and shackles) requires inspection and testing by a which could result in injury to yourself or others.
  • Page 41: Excavator End Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 10 - Excavator End Quickhitch Contents Page No. 03-10-06 Hydraulic Quickhitch ......................03-7 03 - 5 9813/9550-1 03 - 5...
  • Page 42 Notes: 03 - 6 9813/9550-1 03 - 6...
  • Page 43: Hydraulic Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Introduction Introduction ............03-7 The hydraulic quickhitch is installed in place of a Component Identification ......... 03-8 normal attachment at the dipper and tipping link. A hydraulically operated latch mechanism enables Operation ............
  • Page 44: Component Identification

    03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch Component Identification Operation Figure 14. Harness con- The quickhitch latch electrical control system allows nectors (C158, C157, C156) operation of the quickhitch hydraulic latch when the boom and dipper are in the correct position.
  • Page 45 03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch released before the procedure is complete the unlock procedure must be repeated from the start. 03 - 9 9813/9550-1 03 - 9...
  • Page 46 03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch Diagram Figure 17. Electrical Schematic- Quickhitch Locked - Unlock Initiate Q/H SWITCH PRESSED C121 SWITCH: QUICK HITCH CAB BASE EARTH POINT (INT) (EP07) ECU: HYDRAULIC CONTROL ECU (J2) C154 BUCKET CROWD SELECTED...
  • Page 47 03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch Figure 18. Electrical Schematic- Quickhitch Unlocked Q/H BUTTON PRESSED ECU: HYDRAULIC CONTROL ECU (J2) C154 C095 JOYSTICK RH HANDLE CAB BASE EARTH POINT (INT) (EP07) REVOLVER EARTH STUD (EP03) C155...
  • Page 48 03 - Attachments, Couplings and Load Handling 27 - Bucket 27 - Bucket Contents Page No. 03-27-00 General ........................... 03-13 03-27-90 Teeth ..........................03-16 03 - 12 9813/9550-1 03 - 12...
  • Page 49 03 - Attachments, Couplings and Load Handling 27 - Bucket 00 - General 00 - General Introduction Introduction ............ 03-13 A bucket can be installed on many different types Health and Safety .......... 03-14 of excavating machines. The bucket can be directly mounted on to an excavator arm assembly or Remove and Install ........
  • Page 50: Remove And Install

    03 - Attachments, Couplings and Load Handling 27 - Bucket 00 - General Health and Safety Remove and Install CAUTION Stand clear and to one side of the CAUTION Stand clear and to one side of the bucket while you remove the pivot pins. With the bucket while you remove the pivot pins.
  • Page 51 03 - Attachments, Couplings and Load Handling 27 - Bucket 00 - General Install Figure 19. 1. Use a suitable lifting device to position the bucket flat on level ground. 2. Reverse the machine while aligning the dipper end with the bucket tipping lever. 3.
  • Page 52 03 - Attachments, Couplings and Load Handling 27 - Bucket 90 - Teeth 90 - Teeth Introduction Introduction ............ 03-16 Excavator buckets generally have teeth protruding Remove and Install ........03-17 from the cutting edge, to disrupt hard material and avoid wear and tear of the bucket.
  • Page 53: Installation

    03 - Attachments, Couplings and Load Handling 27 - Bucket 90 - Teeth Remove and Install Standard Teeth Remove 1. Make the machine safe. Refer to: PIL 01-03-27. 2. Put the bucket flat on level ground. 3. Stop the engine. 4.
  • Page 54 Notes: 03 - 18 9813/9550-1 03 - 18...
  • Page 55: Body And Framework

    06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-06 Moveable Panel and Cover 06-06-00 General ..........................06-3 06-06-03 Battery Compartment ....................... 06-4 06-06-06 Engine Compartment ....................... 06-5 06-06-09 Hydraulic Compartment ....................06-6 06-06-13 Side Cover ........................06-7 06-15 Excavator End 06-15-00 General...
  • Page 56 Acronyms Glossary Dial Test Indicator FOGS Falling Object Guard System Product Identification Number ROPS Roll-Over Protective Structure TOPS Tip-Over Protective Structure 9813/9550-1 2018-02-20...
  • Page 57 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Moveable Panel and Cover Contents Page No. 06-06-00 General ..........................06-3 06-06-03 Battery Compartment ....................... 06-4 06-06-06 Engine Compartment ....................... 06-5 06-06-09 Hydraulic Compartment ....................06-6 06-06-13 Side Cover ........................
  • Page 58 Notes: 06 - 2 9813/9550-1 06 - 2...
  • Page 59 06 - Body and Framework 06 - Moveable Panel and Cover 00 - General 00 - General Introduction When moved to their maintenance position, the access panels give you access to parts or areas of the machine that are not required during machine operation.
  • Page 60 06 - Body and Framework 06 - Moveable Panel and Cover 03 - Battery Compartment 03 - Battery Compartment Open and Close Open 1. Make the machine safe. 2. Use the ignition key to unlock the cover. 3. Pull the handle to release the latch. 4.
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Js145wJs160w

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