JCB 515-40 TELESCOPIC HANDLER Service Repair Manual Instant Download (515-40 from SN 1627500 to 1769999)

1
Service Manual
515-40
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmissions
Section G - Brakes
Section H - Steering
Section K - Engine

Publication No. 9803/9900-4
World Class Customer Support
Copyright 2004 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.
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
2
Section 1
General Information
Service Manual - 515-40
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmissions
Section G - Brakes
Section H - Steering
Section K - Engine

Publication No. 9803/9900-4
World Class Customer Support
Copyright 2004 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.
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
3
Section 1 - General Information
Contents Page No. Introduction About This
Publication ......................................
.........................................
1-1 Identifying Your Machine .....................
..................................................
.... 1-3 Moving a Disabled Machine
..................................................
.................... 1-8 Transporting the Machine
..................................................
........................ 1-9 Lifting the Machine
..................................................
................................ 1-11 Standard
Torque Settings Zinc Plated Fasteners and
Dacromet Fasteners ...............................
...... 1-13 Hydraulic Connections
..................................................
........................... 1-17 Service
Tools Numerical List .............................
..................................................
........... 1-21 Tool Detail Reference
..................................................
............................ 1-23 Service
Consumables Sealing and Retaining Compounds
..................................................
....... 1-39 Terms and Definitions Colour Coding
..................................................
........................................ 1-41
1-i
1-i
4
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Section 1 - General Information Introduction Abo
ut This Publication
Machine Model and Serial Number
Finally, please remember above all else safety
must come first!
This manual provides information for the
following model(s) in the JCB machine range
Section Numbering
T11-005 The manual is compiled in sections, the
first three are numbered and contain information
as follows
515-40 from SN 1627500 to 1769999
Using the Service Manual

1. General Information - includes torque settings
   and service tools.
2. Care and Safety - includes warnings and cautions
   pertinent to aspects of workshop procedures etc.
3. Maintenance - includes service schedules and
   recommended lubricants for all the machine.

T11-004 This publication is designed for the
benefit of JCB Distributor Service Engineers who
are receiving, or have received, training by JCB
Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and
general techniques associated with the
maintenance and repair of hydraulic earthmoving
equipment.
The remaining sections are alphabetically coded
and deal with Dismantling, Overhaul etc. of
specific components, for example
The illustrations in this publication are for
guidance only. Where the machines differ, the
text and/or the illustration will specify.

1. Attachments
2. Body and Framework, etc.

General warnings in Section 2 are repeated
throughout the manual, as well as specific
warnings. Read all safety statements regularly,
so you do not forget them.
Section contents, technical data, circuit
descriptions, operation descriptions etc. are
inserted at the beginning of each alphabetically
coded section.
Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or damage
is expected as a matter of course. It is expected
that components will be cleaned and lubricated
where appropriate, and that any opened hose or
pipe connections will be blanked to prevent
excessive loss of hydraulic fluid and ingress of
dirt.
Where a torque setting is given as a single
figure it may be varied by plus or minus 3.
Torque figures indicated are for dry threads,
hence for lubricated threads may be reduced by
one third. 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 publication.
1-1
9803/9900-4
6
Section 1 - General Information Introduction About
This Publication
Left Side, Right Side In this manual, 'left' A
and 'right' B mean your left and right when you
are seated correctly in the machine.
447200-2
Fig 1. Cross References T1-004_2 In this
publication, page cross references are made by
presenting the subject title printed in bold,
italic and underlined. It is preceeded by the 'go
to' symbol. The number of the page upon which the
subject begins, is indicated within the brackets.
For example K Cross References ( 1-2).
1-2
9803/9900-4
7
Section 1 - General Information Introduction Ident
ifying Your Machine Identifying Your Machine
Machine Identification Plate
Typical Product Identification Number
The PIN, weight, engine power, year of
manufacture and serial number of the machine are
stamped on the identification plate.
Your machine has an identification plate mounted
as shown. The serial numbers of the machine and
its major units are stamped on the plate.
J C B 5 1 5 4 0 L 9 1 6 2 7 5 0 1 1 2 3 4
Note The machine model and build specification
is indicated by the PIN. Refer to Typical
Product Identification Number (PIN).
The serial number of each major unit is also
stamped on the unit itself. If a major unit is
replaced by a new one, the serial number on the
identification plate will be wrong. Either stamp
the new number of the unit on the identification
plate, or simply stamp out the old number. This
will prevent the wrong unit number being quoted
when replacement parts are ordered.
1 World Manufacturer Identification (3 Digits)
2 Machine Model (5 Digits)
3 Randomly Generated Check Letter (1 Digit)
4 Year of Manufacture (1 Digit)
The machine and engine serial numbers can help
identify exactly the type of equipment you have.
9 2009 B 2011
A 2010 C 2012
5 Machine Serial Number (7 Digits) Each machine
has a unique serial number.
1
2
0
3
POWER OUTLET 12V
F R
1 0
817-18435-2
C091000
Fig 3.
Fig 2. Machine identification plate
1-3
9803/9900-4
8
Section 1 - General Information Introduction Ident
ifying Your Machine The machine PIN is also
stamped onto the fuel tank as at A and onto the
chassis behind the fan assembly as shown at B.
C093310
Fig 4.
1-4
9803/9900-4
9
Section 1 - General Information Introduction Ident
ifying Your Machine
Component Identification Plates Typical Engine
Identification Number The engine data label is
located on the top of the engine. If the engine
is replaced by a new one, the data plate serial
number will be wrong. Either stamp the new number
on the plate or stamp out the old one. This will
prevent the wrong number being quoted when you
order replacement parts.
a b c d e
D 2009 L 04 9999999

1. Type (D Diesel)
2. Series (2009)

c Cylinder layout (L In series)
C089980
Fig 6.
d Number of cylinders (04 4 Cylinder)
Typical Engine Identification Number - Deutz
e Engine Serial Number (7 Digits)
If the engine is replaced by a new one, the data
plate serial number will be wrong. Either stamp
the new number on the plate or stamp out the old
one. This will prevent the wrong number being
quoted when you order replacement parts.
a b c d e
AB 50316 J 000001 2

1. Engine Type (AB 4 cylinder turbo)
2. Engine Parts List

C089970-C3
c Country of Manufacture
Fig 5.
d Engine Serial Number
Note The engine serial number F is also stamped
on the engine. K Fig 6. ( 1-5).
e Year of Manufacture
1-5
9803/9900-4
10
Section 1 - General Information Introduction Ident
ifying Your Machine
Kohler Engine
3 EPA Family ID
4 Tune-up Specifications Injection Timing
Typical Engine Identification Number
5 Tune-up Specifications Injection Opening
Pressure
The engine data label is located on the top of
the engine. If the engine is replaced by a new
one, the data plate serial number will be wrong.
6 PM
7 Fuel Type

• Either stamp the new number on the plate or stamp
  out the old one. This will prevent the wrong
  number being quoted when you order replacement
  parts.
• Engine Model
• Engine Serial Number
• EU Approval Code
• Specification Number
• RPM

1 2 3
6
7
4 5
e
a
C089970-C2
Fig 8.
d
b
c
C089970-C10

• Fig 7.
• Emission Control Information
• The data plate which shows the EPA regulations is
  on the rocker arm cover.
• Power Category
• Engine Displacement

1-6
9803/9900-4
11
Section 1 - General Information Introduction Ident
ifying Your Machine
FOPS Data Plate
ROPS Data Plate
WARNING
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.
You could be killed or seriously injured if you
operate a machine with a damaged or missing
ROPS/FOPS. If the Roll Over Protection Structure
(ROPS)/Falling Objects Protection Structure
(FOPS) has been in an accident, do not use the
machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS certification.
8-2-8-17
If the machine is used in any application where
there is a risk of falling objects then a
falling-objects protective structure (FOPS) must
be installed. For further information contact
your JCB Dealer
INT-2-1-9_6
The falling objects protection structure (FOPS)
is fitted with a dataplate. The dataplate
indicates what level protection the structure
provides.
WARNING
Seat Belts The ROPS/FOPS is designed to give you
protection in an accident. If you do not wear
your seat belt, you could be thrown out of the
machine and crushed. You must wear a seat belt
when using the machine. Fasten the seat belt
before starting the engine.
There are two levels of FOPS
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.
0153
The machine is built to the ROPS standard and has
a data plate attached to the frame. K Fig 10.
( 1-7).
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.
For an example of the ROPS data plate, refer to K
Fig 10. ( 1-7).
For an example of the FOPS data plate, refer to K
Fig 9. ( 1-7).
ROPS COMPLIES TO EN ISO 34712008
FOPS COMPLIES TO EN ISO 34492008 LEVEL 1
515-40
J.C.B.CAB SYSTEMS LAKESIDE WORKS ROCESTER
UTTOXETER,STAFFS ST14 5JP ENGLAND
MAXIMUM UNLADEN MASS 5000kg.
ROPS COMPLIES TO EN ISO 34712008
FOPS COMPLIES TO EN ISO 34492008 LEVEL 1
515-40
J.C.B.CAB SYSTEMS LAKESIDE WORKS ROCESTER
UTTOXETER,STAFFS ST14 5JP ENGLAND
YEAR
CAB PART No 332/W1466
SERIAL No
333/P2846
MAXIMUM UNLADEN MASS 5000kg.
C090690
YEAR
CAB PART No 332/W1466
Fig 10.
SERIAL No
333/P2846
C090690
Fig 9.
1-7
9803/9900-4
12
Section 1 - General Information Introduction Movin
g a Disabled Machine Moving a Disabled Machine
Important This procedure should only be carried
out be a qualified engineer. If you have any
queries concerning this procedure, consult your
local JCB Distributor.
4 Open the bypass valve, as follows
a Remove the operators seat base to get access
to the transmission pump. Refer to Maintenance,
Operators Seat Base.
CAUTION
The transmission will be damaged, if the machine
is moved unless the transmission pump is prepared
for towing.
b Unscrew plug A by three full turns.
5 Remove the wheel chocks from each wheel and
tow the machine to a place of repair at a maximum
speed of 6 mph (10 kph). Tow the machine the
minimum distance necessary (maximum one mile).
When towing is complete, place chocks both sides
of each wheel.
4-2-5-6
CAUTION
Recovery Hitch The counterweight is fitted with a
recovery hitch which must not be used for towing.
6 Tighten the plug A to close the bypass valve.
2-1-1-11_2
7 Remove the tow bar and wheel blocks.
CAUTION
8 Replace the operator seat base.

• Towing a machine too far or too fast can damage
  the transmission. Do not tow the machine further
  than one mile. Use a trailer for greater
  distances. When towing do not travel faster than
  6 mph (10 km/h).
• Use a rigid draw-bar. If a towing chain must be
  used, then use two towing vehicles. One towing
  vehicle should be coupled to the front of the
  disabled machine. The other towing vehicle should
  be coupled to the rear of the disabled machine,
  to provide braking power.
• The towing vehicle(s) must have enough pulling
  and braking power to move and stop the machine.
• 2-2-7-34-1
• Using suitable lifting equipment, remove any
  payload from the machine.
• Attach a rigid tow bar between a suitable
  connection point on the machine and the towing
  vehicle.

C091480
Fig 11.
3 Place blocks both sides of each wheel on the
disabled machine.
Important If the machine is to be towed the
transmission bypass valve must be adjusted as
shown below. The machine should only be towed the
minimum distance required to load it onto a
transporter. The transporter should be positioned
as close as possible to the machine.
1-8
9803/9900-4
13
Section 1 - General Information Introduction Trans
porting the Machine Transporting the Machine
g Switch off the engine.
WARNING
The safe transit of the load is the
responsibility of the transport contractor and
driver. Any machine, attachments or parts that
may move during transit must be adequately
secured.
h Put blocks at the front and rear of all four
tyres.
i Secure the cab.
j Cover the exhaust pipe. Loading a disabled
machine onto the trailer
5-2-5-9
Important Use only the tie down anchor points
specified.
Note Before transporting the machine make sure
you will be obeying the rules and laws of all the
areas that the machine will be carried through.
a Align the trailer with the rear of the machine.
Note The trailer must be equipped with a winch
to pull the machine aboard.
Make sure that the transporting vehicle is
suitable. See Static Dimensions (SPECIFICATIONS
section) for the dimensions of your machine.
b Make sure the ramps are correctly in place and
secure.
c Connect the winch cable onto the recovery
hitch on the back of the machine.
WARNING
Before moving the machine onto the trailer, make
sure that the trailer and ramp are free from oil,
grease and ice. Remove oil, grease and ice from
the machine tyres. Make sure the machine will not
foul on the ramp angle. See Static Dimensions in
SPECIFICATION section for the minimum ground
clearance of your machine.
d Prepare the machine for recovery. K Moving a
Disabled Machine ( 1-8)
e Operate the winch and pull the machine onto
the trailer until the shovel/attachment is well
inside the back end of the trailer.

• 2-2-7-5_1
• Place blocks at the front and rear of the trailer
  wheels.
• Move the machine onto the trailer.

f Engage the park brake.
g Put blocks at the front and rear of all four
tyres.
h Lower the carriage onto the trailer.
Loading a serviceable machine onto the trailer
i Check that the overall height of the load is
within regulations. Adjust if necessary.
a Make sure the ramps are correctly in place and
secure.
j Secure the cab.
b Set the boom.
k Cover the exhaust pipe. 3 Anchor the machine
to the trailer with chains. The anchor points are
shown on the illustration.
c Carefully drive the machine onto the trailer.
d Engage the park brake and set the drive to
neutral.
4 Measure the maximum height of the machine from
the ground. Make sure the truck driver knows the
clearance height before he drives away.
e Lower the carriage onto the trailer.
f Check that the overall height of the load is
within regulations. Adjust if necessary.
1-9
9803/9900-4
14
Section 1 - General Information Introduction Trans
porting the Machine
T043110-C2
Fig 12. Hooks can be used on the anchor points
1-10
9803/9900-4
15
Section 1 - General Information Introduction Lifti
ng the Machine Lifting the Machine
Introduction
Do not use the anchor points to lift the machine.
If the anchor points are used, the machine will
not lift evenly and become unstable.
B
A
The lifting-eyes in the top surface of the
counterweight are for the removal and
installation of the counterweight only. The
lifting-eyes can not support the weight of the
machine. To safely lift the machine, the Lifting
Point Option (333/ R3798) must be installed,
refer to your JCB Dealer.

• Preparing the Machine
• Stop the machine on level, solid ground.
• Engage the park brake and set the drive to
  neutral.
• Retract the boom.
• Lower the boom fully, then lift it slightly.

333-R3798
Fig 13.
WARNING
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.
5 Tilt the carriage back to keep the heel of the
forks 300mm (12in.) above the ground.
6 Switch off the engine and remove the starter
key.
7 Isolate the battery.
INT-1-3-7_2
8 Remove all loose equipment.
10 Attach the lifting equipment to the
D-shackles.
9 Attach the D-shackles
11 Install a spreader-frame to prevent damage to
the machine.
Attach a D-shackle A to the front sling-point.
The front sling-point is a permanent fixture,
which is welded to the steel fuel tank. The fuel
tank is part of the chassis, which gives the
sling-point extra strength.
Attach a D-shackle B to the two rear
sling-points. The two rear sling-points are
attached to the chassis with M16 bolts. Note
The D-shackles each have a safe working load of
five tonnes.
1-11
9803/9900-4
16
Section 1 - General Information Introduction Lifti
ng the Machine

• Lifting the Machine
• DANGER
• Do not stand underneath the raised load during
  the lowering procedure. Stand clear and to one
  side until the load has been safely lowered. Make
  sure that the area is clear of other people
  before lowering the load. If you do not follow
  these precautions you or others could be killed
  or seriously injured.
• 2-3-5-3
• Make sure that the lifting-eye is directly above
  the centre of the machine.
• Lift the machine.
• Make sure that the lifting equipment does not
  catch the machine.

1-12
9803/9900-4
17
Section 2
Care and Safety
Service Manual - 515-40
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmissions
Section G - Brakes
Section H - Steering
Section K - Engine

Publication No. 9803/9900-2
World Class Customer Support
Copyright 2004 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.
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
18
Section 2 - Care and Safety
Contents Page No. Safety Notices Important
Information .....................................
...........................................
2-1 Safety Check List ............................
..................................................
......... 2-2 Safety Labels ......................
..................................................
................... 2-13
2-i
2-i
19
Section 2 - Care and Safety
Safety Notices Important Information T1-042
The Operator Manual
Safety Warnings
WARNING
This safety alert system identifies important
safety messages in this manual. When you see
this symbol, be alert, your safety is involved,
carefuly read the message that follows, and
inform other operators.
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator Manual. You must
understand and follow the instructions in the
Operator Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
In this publication and on the machine, there are
safety notices. Each notice starts with a signal
word. The signal word meanings are given below.
INT-1-4-2
Do not operate the machine without an Operator
Manual, or if there is anything on the machine
you do not understand.
DANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable
that the operator (or others) could be killed or
seriously injured.
Treat the Operator Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator Manual immediately if it is lost,
damaged or becomes unreadable.
INT-1-2-1
WARNING Denotes a hazard exists. If proper
precautions are not taken, the operator (or
others) could be killed or seriously
injured. INT-1-2-2 CAUTION Denotes a reminder of
safety practices. Failure to follow these safety
practices could result in injury to the operator
(or others) and possible damage to the
machine. INT-1-2-3
2-1
9803/9900-2
20
Section 2 - Care and Safety Safety Notices Safety
Check List Safety Check List P5-1010_3
Safety - Yours and Others
General Safety
INT-1-3-1_3 All machinery can be hazardous. When
a machine is correctly operated and properly
maintained, it is a safe machine to work with.
But when it is carelessly operated or poorly
maintained it can become a danger to you (the
operator) and others.
T1-043
WARNING
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 Manual instructs you
on the machine, its controls and its safe
operation it is not a training manual. If you
are a new operator, get yourself trained in the
skills of using a machine before trying to work
with it. If you don't, you will not do your job
well, and you will be a danger to yourself and
others.
In this manual and on the machine you will find
warning messages. Read and understand them. They
tell you of potential hazards and how to avoid
them. If you do not fully understand the warning
messages, ask your employer or JCB distributor to
explain them.
But 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 what
hazards there might be and how to avoid them.
INT-1-4-1
WARNING
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.
Do not work with the machine until you are sure
that you can control it.
Do not start any job until you are sure that you
and those around you will be safe.
INT-1-3-5
WARNING
If you are unsure of anything, about the machine
or the job, ask someone who knows. Do not assume
anything.
Clothing You can be injured if you do not wear
the proper clothing. Loose clothing can get
caught in the machinery. Wear protective clothing
to suit the job. Examples of protective clothing
are a hard hat, safety shoes, safety glasses, a
well fitting overall, ear- protectors and
industrial gloves. Keep cuffs fastened. Do not
wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
Remember
BE CAREFUL BE ALERT BE SAFE
INT-1-3-6_2
WARNING 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. INT-1-3-9_2
2-2
9803/9900-2
21
Section 2 - Care and Safety Safety Notices Safety
Check List
WARNING
DANGER
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.
Lightning Lightning can kill you. Do not use the
machine if there is lightning in your area.
5-1-1-2
8-1-2-4
WARNING
WARNING
Machine Modifications This machine is
manufactured in compliance with legislative and
other requirements. It should not be altered in
any way which could affect or invalidate any of
these requirements. For advice consult your JCB
Distributor.
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.
INT-1-3-10_2 Switch off and do not use your
mobile phone when refuelling the
machine. INT-3-3-9 WARNING 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. INT-1-3-7_2 WARNING 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. 13-2-3-7_3 WARNING Raised Machine NEVER
position yourself or any part of your body under
a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or
be killed. INT-3-3-7_1
2-3
9803/9900-2
22
Section 2 - Care and Safety Safety Notices Safety
Check List
Operating Safety
WARNING
Work Sites Work sites can be hazardous. Inspect
the site before working on it. You could be
killed or injured if the ground gives way under
your machine or if piled material collapses onto
it. Check for potholes and hidden debris, logs,
ironwork etc. Any of these could cause you to
lose control of your machine. Check for utilities
such as electric cables (overhead and
underground), gas and water pipes etc. Mark the
positions of the underground cables and pipes.
Make sure that you have enough clearance
beneath overhead cables and structures.
WARNING
Machine Condition A defective machine can injure
you or others. Do not operate a machine which is
defective or has missing parts. Make sure the
maintenance procedures in this manual are
completed before using the machine.
INT-2-1-2_2
WARNING
Machine Limits Operating the machine beyond its
design limits can damage the machine, it can also
be dangerous. Do not operate the machine outside
its limits. Do not try to upgrade the machine
performance with unapproved modifications.
INT-2-2-1_2
WARNING
Communications Bad communications can cause
accidents. Keep people around you informed of
what you will be doing. If you will be working
with other people, make sure any hand signals
that may be used are understood by everybody.
Work sites can be noisy, do not rely on spoken
commands.
INT-2-1-4
WARNING
Engine/Steering Failure If the engine or steering
fails, stop the machine as quickly as possible.
Do not operate the machine until the fault has
been corrected.
INT-2-2-3
WARNING
INT-2-1-5
Parking An incorrectly parked machine can move
without an operator. Follow the instructions in
the Operator Manual to park the machine correctly.
WARNING
Exhaust Gases Breathing the machine exhaust gases
can harm and possibly kill you. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, fit an
exhaust extension. If you begin to feel drowsy,
stop the machine at once and get into fresh air.
INT-2-2-4_2
WARNING
Banks and Trenches Banked material and trenches
can collapse. Do not work or drive too close to
banks and trenches where there is danger of
collapse.
INT-2-1-10_2
INT-2-2-5
WARNING Safety Barriers Unguarded machines in
public places can be dangerous. In public
places, or where your visibility is reduced,
place barriers around the work area to keep
people away. INT-2-2-8
2-4
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Section 2 - Care and Safety Safety Notices Safety
Check List
DANGER
WARNING
Sparks Explosions and fire can be caused by
sparks from the exhaust or the electrical system.
Do not use the machine in closed areas where
there is flammable material, vapour or dust.
Keep the machine controls clean and dry. Your
hands and feet could slide off slippery controls.
If that happens you could lose control of the
machine.
2-2-3-6
WARNING
INT-2-2-10
Electrical Power Cables You could be electrocuted
or badly burned if you get the machine or its
attachments too close to electrical power cables.
WARNING
Hazardous Atmospheres This machine is designed
for use in normal out door atmospheric
conditions. It should not be used in an enclosed
area without adequate ventilation. Do not use
the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or
dust, without first consulting your JCB
Distributor.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near
electric power lines.
Before you start using the machine, check with
your electricity supplier if there are any buried
power cables on the site.
INT-2-1-14
CAUTION
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
Regulations Obey all laws, work site and local
regulations which affect you and your machine.
INT-1-3-3
2-2-5-4
CAUTION
WARNING
Practice You or others can be killed or seriously
injured if you do unfamiliar operations without
first practising them. Practise away from the
work site on a clear area. Keep other people
away. Do not perform new operations until you are
sure you can do them safely.
If you have an attachment which is not covered in
the Operator Manual do not install it, use it or
remove it until you have obtained, read and
understood the pertinent information. Install
attachments only on the machines for which they
were designed.
5-5-1-1_2
INT-2-1-1
WARNING
WARNING
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or
others.
Airborne particles of light combustible material
such as straw, grass, wood shavings, etc. must
not be allowed to accumulate within the engine
compartment or in the propshaft guards (when
fitted). Inspect these areas frequently and clean
at the beginning of each work shift or more often
if required. Before opening the engine cover,
ensure that the top is clear of debris.
The use of non-approved attachments could
invalidate your warranty.
2-4-5-2_1
5-3-1-12_3
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Section 2 - Care and Safety Safety Notices Safety
Check List
DANGER
CAUTION
Working Platform Using the machine as a
working platform is hazardous you can fall off
and be killed or injured. Never use the machine
as a working platform.
Fork Spacing Loads can fall off incorrectly
spaced forks. Always space the forks correctly
for the load. Make sure the forks are completely
under the load before lifting.
5-1-5-9
5-1-4-2
WARNING
CAUTION
Machine Safety Stop work at once if a fault
develops. Abnormal sounds and smells can be signs
of trouble. Inspect and repair before resuming
work.
One-Fork Lifting A load lifted on one fork can
slip off. Never lift a load with one fork.
5-1-4-3
8-1-2-3
CAUTION
WARNING
Unloading Never unload the forks by stopping the
machine suddenly. Follow the procedures in the
Operator Manual for unloading.
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.
5-1-4-4_2
10-1-1-40
CAUTION
WARNING
Uneven Ground Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
Travelling at High Speeds Travelling at high
speeds can cause accidents. Do not reverse in a
high gear with full throttle. Always travel at a
safe speed to suit working conditions.
5-1-4-5
WARNING
INT-5-3-3
Scaffolding Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation
capacity.
WARNING
The engine has exposed rotating parts. Switch OFF
the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
5-1-4-6
CAUTION
5-2-6-5
Overhead Clearance A raised boom can strike
overhead objects. Always check for overhead
clearance before raising the boom.
WARNING
You could be killed or seriously injured if you
operate a machine with a damaged or missing
ROPS/FOPS. If the Roll Over Protection Structure
(ROPS)/Falling Objects Protection Structure
(FOPS) has been in an accident, do not use the
machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS certification.
5-1-5-1
WARNING
Boom/Machine Travel Operating the boom while you
travel can cause accidents. You will not have
total control of the machine. Never operate the
boom when you travel.
INT-2-1-9_6
5-1-5-2_2
2-6
9803/9900-2
25
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26
Section 2 - Care and Safety Safety Notices Safety
Check List
DANGER
WARNING
Forks/Working Platform Using the forks alone as a
working platform is hazardous you can fall off
and be killed or injured. Never use the forks as
a working platform.
Visibility Accidents can be caused by working in
poor visibility. Use your lights to improve
visibility. Keep the road lights, windows and
mirrors clean.
5-1-5-3
Do not operate the machine if you cannot see
clearly.
WARNING
5-1-4-7
Forks/Turning The forks project in front of the
machine. Make sure there is enough clearance for
the forks when making turns.
WARNING
Keep Your Hands and Feet Inside the
Vehicle 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.
5-1-5-4_2
WARNING
13-1-1-17
High Loads A high load can block your view and
reduce the machine's stability. Travel with the
load low to the ground. Travel slowly and with
caution over rough, muddy or loose surfaces.
WARNING
Controls You or others can be killed or
seriously injured if you operate the control
levers from outside the machine. Operate the
control levers only when you are correctly seated.
5-1-3-2
WARNING
0179_2
Slopes When transporting a load on a slope, drive
slowly and keep the load uphill of the machine.
This will increase stability.
CAUTION
Passengers Passengers in or on the machine can
cause accidents. Do not carry passengers.
5-1-4-1
WARNING
INT-2-2-2_1
Hillsides Operating the machine on hillsides can
be dangerous if proper precautions are not taken.
Ground conditions can be changed by rain, snow,
ice etc. Check the site carefully. Operate in
first gear on hillsides, when applicable, keep
all attachments low to the ground. Never coast
down a hill with the engine off or the
transmission in neutral.
WARNING
Fires If your machine is equipped with a fire
extinguisher, make sure it is checked regularly.
Keep it in the correct machine location until you
need to use it.
Do not use water to put out a machine fire, you
could spread an oil fire or get a shock from an
electrical fire. Use carbon dioxide, dry
chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible.
Firefighters should use self- contained breathing
apparatus.
INT-2-2-7
INT-3-2-7_2
2-7
2-7
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27
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