Section 2

Care and Safety

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine

Publication No.
9803/6540-1



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 Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section 2 - Care and Safety

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 Section 2 - Care and Safety

Contents Page No.

Safety Check List
Safety Notices ......................................................................................... 2 - 1
Safety - Yours and Others ....................................................................... 2 - 2
General Safety ........................................................................................ 2 - 3
Operating Safety ..................................................................................... 2 - 4
Maintenance Safety ................................................................................. 2 - 6
Safety Decals .......................................................................................... 2 - 9
Safety Decal Recognition ................................................................. 2 - 10
Chart Definitions ............................................................................... 2 - 13

2-i 2-i
 Section 2 - Care and Safety

Contents Page No.

2 - ii 2 - ii
 Section 2 - Care and Safety

Safety Check List

Safety Notices

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.

!MDANGER
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.
INT-1-2-1

!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2

!MCAUTION
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

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 Section 2 - Care and Safety
Safety Check List
Safety - Yours and Others

Safety - Yours and Others

All construction and agricultural equipment can be

hazardous. When a JCB 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.

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.

If you are unsure of anything, about the machine or the

job, ask someone who knows. Do not assume
anything.

Remember

– BE CAREFUL
– BE ALERT
– BE SAFE
GEN-1-6

As well as the warnings in the following pages, specific

warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.

Note: This section includes a certain amount of operating

safety information. But remember that whenever you drive
the machine or operate its controls, you are in effect a
machine operator. Therefore you should read and
understand the information given in the Operator
Handbook before driving the machine or operating its
controls.

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 Section 2 - Care and Safety
Safety Check List
General Safety

General Safety

!MWARNING !MWARNING
Operator Manual Clothing
You and others can be injured if you operate or You can be injured if you do not wear the proper
maintain the machine without first studying the clothing. Loose clothing can get caught in the
Operator Manual. Read the safety instructions before machinery. Wear protective clothing to suit the job.
operating the machine. If you do not understand Examples of protective clothing are: a hard hat, safety
anything, ask your employer or JCB dealer to explain shoes, safety glasses, a well fitting overall, ear-
it. Keep the Operator Manual clean and in good protectors and industrial gloves. Keep cuffs fastened.
condition. Do not operate the machine without an Do not wear a necktie or scarf. Keep long hair
Operator Manual in the cab, or if there is anything on restrained.
the machine you do not understand. INT-1-3-6
INT-1-3-2_2

!MWARNING
!MWARNING Lifting Equipment
Decals You can be injured if you use faulty lifting equipment.
Decals on the machine warn you of particular hazards. Make sure that lifting equipment is in good condition.
You can be injured if you do not obey the decal safety Make sure that lifting tackle complies with all local
instructions. regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
Each decal is attached close to a part of the machine INT-1-3-7
where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.
!MWARNING
Raised Equipment
Keep all decals clean and readable. Replace lost or Raised equipment can fall and injure you. Do not walk
damaged decals. Each decal has a part number or work under raised equipment unless safely
printed on it, use this number to order a new decal supported.
from your JCB distributor. 13-1-1-6
INT-3-3-3_1

!MDANGER
!MWARNING Before removing the boom from the machine, ensure
Care and Alertness that the counterweight is adequately supported as in
All the time you are working with or on the machine, certain ground conditions the machine could tip
take care and stay alert. Always be careful. Always be backwards. Never travel or transport the machine with
alert for hazards. the boom removed.
INT-1-3-5 BF-6-3

!MWARNING
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

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 Section 2 - Care and Safety
Safety Check List
Operating Safety

Operating Safety

!MWARNING !MWARNING
Practice Visibility
You or others can be killed or seriously injured if you Accidents can be caused by working in poor visibility.
do unfamiliar operations without first practising them. Use your lights to improve visibility. Keep the road
Practise away from the work site on a clear area. Keep lights, windows and mirrors clean.
other people away. Do not perform new operations
until you are sure you can do them safely. Do not operate the machine if you cannot see clearly.
INT-2-1-1 5-1-4-7

!MWARNING !MWARNING
Machine Condition Machine Limits
A defective machine can injure you or others. Do not Operating the machine beyond its design limits can
operate a machine which is defective or has missing damage the machine, it can also be dangerous. Do not
parts. Make sure the maintenance procedures in this operate the machine outside its limits. Do not try to
manual are completed before using the machine. upgrade the machine performance with unapproved
INT-2-1-2_2 modifications.
INT-2-1-4

!MCAUTION
If you have an attachment which is not covered in the
!MWARNING
Operator Manual do not install it, use it or remove it Exhaust Gases
until you have obtained, read and understood the Breathing the machine exhaust gases can harm and
pertinent information. Install attachments only on the possibly kill you. Do not operate the machine in closed
machines for which they were designed. spaces without making sure there is good ventilation.
5-5-1-1_2 If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
!MWARNING fresh air.
INT-2-1-10_2
Entering/Leaving
Entering or leaving the cab or canopy must only be
made where steps and handrails are provided. Always
!MDANGER
face the machine when entering and leaving. Make Sparks
sure the step(s), handrails and your boot soles are Explosions and fire can be caused by sparks from the
clean and dry. Do not jump from the machine. Do not exhaust or the electrical system. Do not use the
use the machine controls as handholds, use the machine in closed areas where there is flammable
handrails. material, vapour or dust.
INT-2-1-7_1 INT-2-2-10

!MWARNING !MWARNING
Controls Engine
You or others can be killed or seriously injured if you The engine has exposed rotating parts. Do not open
operate the control levers from outside the cab. the engine cover while the engine is running. Do not
Operate the control levers only when you are correctly use the machine with the cover open.
seated inside the cab. INT-2-1-6_1
INT-2-1-3

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 Section 2 - Care and Safety
Safety Check List
Operating Safety

!MCAUTION !MWARNING
Passengers Airborne particles of light combustible material such
Passengers in or on the machine can cause accidents. as straw, grass, wood shavings, etc. must not be
Do not carry passengers. allowed to accumulate within the engine compartment
INT-2-2-2_1 or in the propshaft guards (when fitted). Inspect these
areas frequently and clean at the beginning of each
!MWARNING work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris.
Safe Working Loads 5-3-1-12_3
Overloading the machine can damage it and make it
unstable. Study the specifications in the Operator
Manual before using the machine.
!MWARNING
7-1-1-8_2 Electrical Power Cables
You could be electrocuted or badly burned if you get
!MWARNING the machine or its attachments too close to electrical
power cables.
The Long Reach is larger and higher than a normal
excavating rig. You must take extra care when you are You are strongly advised to make sure that the safety
working in dangerous or restricted height locations arrangements on site comply with the local laws and
such as under power lines, bridges, etc. regulations concerning work near electric power lines.
8-2-8-10
Before you start using the machine, check with your
!MWARNING electricity supplier if there are any buried power
cables on the site.
When using Quick Hitch Type 2, the attachment can
become unexpectedly disengaged from the Quick There is a minimum clearance required for working
Hitch, when any of the following occurs: beneath overhead power cables. You must obtain
details from your local electricity supplier.
Power failure to the Electronic Control Unit (ECU). 2-2-5-4

When the redundancy switch is engaged.

!MCAUTION
If an electrical component in the Quick Hitch system With certain combinations of bucket or attachment
should fail. and boom/dipper configuration, it is possible for the
0178 bucket teeth or attachment extremities to contact and
cause damage to the structure of the machine. Check
!MCAUTION the limit of free movement as the dipper is brought in
towards the machine.
Because of the extra length and height of the Long 8-2-5-2
Reach boom and dipper, you must be very careful
when slewing. Do not slew quickly and strike the
dipper against obstacles. You may cause severe
!MWARNING
damage to the rig structure. Hazardous Atmospheres
8-2-8-11 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.
INT-2-1-14

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 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

Maintenance Safety

!MWARNING !MWARNING
Repairs Diesel Fuel
If your machine does not function correctly in any way, Diesel fuel is flammable; keep naked flames away from
get it repaired straight away. Neglect of necessary the fuel system. Do not smoke while refuelling or
repairs could result in an accident or affect your working on the fuel system. Do not refuel with the
health. Do not try to do repairs or any other type of engine running. There could be a fire and injury if you
maintenance work you do not understand. To avoid do not follow these precautions.
injury and/or damage get the work done by a specialist INT-3-2-2_1
engineer.
GEN-1-5_2
!MWARNING
!MWARNING Oil
Oil is toxic. If you swallow any oil, do not induce
Metal Splinters vomiting, seek medical advice. Used engine oil
You can be injured by flying metal splinters when contains harmful contaminants which can cause skin
driving metal pins in or out. Use a soft faced hammer cancer. Do not handle used engine oil more than
or copper pin to remove and fit metal pins. Always necessary. Always use barrier cream or wear gloves to
wear safety glasses. prevent skin contact. Wash skin contaminated with oil
INT-3-1-3_2 thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
!MWARNING INT-3-2-3

Petrol
Do not use petrol in this machine. Do not mix petrol
!MWARNING
with the diesel fuel; in storage tanks the petrol will rise Fluid Under Pressure
to the top and form flammable vapours. Fine jets of fluid at high pressure can penetrate the
INT-3-1-6 skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
!MWARNING cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
Machine Modifications skin, get medical help immediately.
This machine is manufactured in compliance with INT-3-1-10_2
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
!MWARNING
Distributor. Fires
INT-1-3-10_2 If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
!MWARNING machine location until you need to use it.

Electrical Circuits Do not use water to put out a machine fire, you could
Understand the electrical circuit before connecting or spread an oil fire or get a shock from an electrical fire.
disconnecting an electrical component. A wrong Use carbon dioxide, dry chemical or foam
connection can cause injury and/or damage. extinguishers. Contact your nearest fire department as
INT-3-1-4 quickly as possible. Firefighters should use self-
contained breathing apparatus.
INT-3-2-7_2

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 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

!MWARNING !MCAUTION
Hydraulic Pressure Rams
Hydraulic fluid at system pressure can injure you. The efficiency of the rams will be affected if they are
Before connecting or removing any hydraulic hose, not kept free of solidified dirt. Clean dirt from around
residual hydraulic pressure trapped in the service the rams regularly. When leaving or parking the
hose line must be vented. Make sure the hose service machine, close all rams if possible to reduce the risk
line has been vented before connecting or removing of weather corrosion.
hoses. Make sure the engine cannot be started while INT-3-2-10
the hoses are open.
INT-3-1-11_2
!MCAUTION
!MWARNING 'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and
Hot Coolant gaskets can cause leakages and possible accidents.
The cooling system is pressurised when the engine is Renew whenever disturbed unless otherwise
hot. Hot coolant can spray out when you remove the instructed. Do not use Triochloroethane or paint
filler cap. Let the system cool before removing the thinners near 'O' rings and seals.
filler cap. To remove the cap; turn it to the first notch INT-3-2-12
and let the system pressure escape, then remove the
cap.
INT-3-2-9_1
!MWARNING
If you try to charge a frozen battery, or jump start and
!MCAUTION run the engine, the battery could explode. Do not use
a battery if its electrolyte is frozen. To prevent the
Cleaning battery electrolyte from freezing, keep the battery at
Cleaning metal parts with incorrect solvents can cause full charge.
corrosion. Use only recommended cleaning agents 0125
and solvents.
INT-3-2-11
!MWARNING
!MWARNING Battery Gases
Batteries give off explosive gases. Keep flames and
Hydraulic Hoses sparks away from the battery. Do not smoke close to
Damaged hoses can cause fatal accidents. Inspect the the battery. Make sure there is good ventilation in
hoses regularly for: closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
– Damaged hose ends the terminals with metal; use a hydrometer or
– Chafed outer covers voltmeter.
INT-3-1-8
– Ballooned outer covers
– Kinked or crushed hoses
– Embedded armouring in outer covers
!MWARNING
– Displaced end fittings. Battery Terminals
The machine is negatively earthed. Always connect
INT-3-3-2 the negative pole of the battery to earth.

!MWARNING When connecting the battery, connect the earth (-) lead
last.
Soft Ground
A machine can sink into soft ground. Never work When disconnecting the battery, disconnect the earth
under a machine on soft ground. (-) lead first.
INT-3-2-4
INT-3-1-9

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 Section 2 - Care and Safety
Safety Check List
Maintenance Safety

!MWARNING
Certain seals and gaskets (e.g. crankshaft oil seal) on
JCB machines contain fluoroelastomeric materials
such as Viton, Fluorel and Technoflon.
Fluoroelastomeric materials subjected to high
temperatures can produce highly corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

New fluoroelastomeric components at ambient

temperature require no special safety precautions.

Used fluoroelastomeric components whose

temperatures have not exceeded 300°C (572°F) require
no special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to the
next paragraph for safety instructions DO NOT TOUCH
COMPONENT OR SURROUNDING AREA.

Used fluoroelastomeric components subjected to

temperatures greater than 300°C (572°F) (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn:

1 Thoroughly wash contaminated area with 10%

calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains.

2 Thoroughly wash contaminated area with

detergent and water.

3 Contain all removed material, gloves etc. used in

this operation in sealed plastic bags and dispose
of in accordance with Local Authority
Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

INT-3-3-5_3

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 Section 2 - Care and Safety
Safety Check List
Safety Decals

Safety Decals

!MWARNING
Decals
Decals on the machine warn you of particular hazards.
You can be injured if you do not obey the decal safety
instructions.

Each decal is attached close to a part of the machine

where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.

Keep all decals clean and readable. Replace lost or

damaged decals. Each decal has a part number
printed on it, use this number to order a new decal
from your JCB distributor.
INT-3-3-3_1

!MWARNING
If you need eye-glasses for reading, make sure you
wear them when reading the safety decals. Decals are
strategically placed around the machine to remind you
of possible hazards. Do not over-stretch or place
yourself in dangerous positions to read the decals.
INT-3-3-4_1

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 Section 2 - Care and Safety
Safety Check List
Safety Decals

Safety Decal Recognition

Table 1.
Label Part No. Definition
A 817/19470 Warning, Arm or bucket may move; keep clear.
B JLP0283 Warning, Do not use excavator for lifting loads.
C 817/19660 Instruction, Cold weather conditions. Refer to operators manual.
D 817/18535 1-Warning, Coolant under pressure. 2-Warning, Risk of severing hands/fingers in rotating parts.
3-Warning, Hot surfaces. 4-Remove ignition key and refer to operator manual and maintenance
manual.
E 817/18536 Warning, Hot surfaces; Keep hands away.
F 817/18537 Warning, High pressure and hot coolant/system; Keep hands away.
G 817/18538 Warning, Risk of severing finger/hand in rotating parts; Keep hands away.
H 817/18566 Do not walk or place any body weight in this area.
K 817/18528 Warning counterweight or whole machine may move; Keep clear.
L 817/02370 Warning, 24V.
M 817/70003 Warning, Risk of trapping fingers/hand in door; Keep hands away.
N JHP0111 Warning. No hosing or jet washing in cab.
P 817/70116 Warning, Unexpected movement of part or whole machine; Move lock lever to the lock position.
Q 817/18541 Warning, Read the operation and maintenance manual.
R 817/19960 Warning, High pressure hydraulic system; 1-Stop the engine. 2-Depress the rubber booted
pressure relief valve until all the tank pressure is released. 3-Remove filler plug/breather
assembly as required.
S 817/18527 Diesel fuel, Warning, Flammable substance; No ignition source.
T Lubrication chart.Refer to `Chart Definitions' for details.
V Lifting chart. Refer to `Chart Definitions' for details.
W 817/70117 1-Instruction, Bucket can foul the boom when dipper is swinging inwards. Maintain clearance
between bucket and arm. 2-Warning, Danger of collision, Maintain clearance between bucket
and cab. 3-Warning, Risk of tripping; raise the control lock lever before exiting. 4-Warning, Risk
of injury by crushing; Do not lean out of the front window. 5-Warning, Risk of electrocution;
Maintain the minimum clearance recommended by your local electricitysupplier.
X 817/18531 Warning, Edges without protective railings; Keep clear of edges.
Y 817/18532 Warning, Hoses that may eject a high velocity jet capable of penetrating the skin; Remove
ignition key and refer to operator manual and maintenance manual.

2 - 10 9803/6540-1 2 - 10
 Section 2 - Care and Safety
Safety Check List
Safety Decals

817/18535

817/18536 817/18537 817/18538

JLP0283

81 7/ 18 54 2

24 V

817/18541

817/18533 817/1852 8

Fig 1.

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 Section 2 - Care and Safety
Safety Check List
Safety Decals

Fig 2.

2 - 12 9803/6540-1 2 - 12
 Section 2 - Care and Safety
Safety Check List
Safety Decals

Chart Definitions Table 3. Icon Definitions

Typical Lubrication Chart Excavator grease

Engine oil change

Engine oil filter change

Engine coolant change

Fig 3. Engine air filter change

Table 2. Location Identifier

A Travel gearbox
B Engine oil filter
Engine air filter clean
C Plexus filter
D Engine oil pan
E Engine cooling system
F Servo oil filter Transmission oil change
G Fuel filter
H Swing ring bearing
J Air cleaner, outer
Transmission oil level
K Air cleaner, inner
L Drain line filter
M Fuel separator
N Hydraulic return filter Fuel (diesel)
P Hydraulic tank air breather
Q Suction strainer
R Hydraulic tank
Fuel filter change
S Swing ring gear teeth
T Fuel tank
U Slew gearbox
V Boom/arm grease points Hydraulic oil change
W Boom/arm grease points

2 - 13 9803/6540-1 2 - 13
 Section 2 - Care and Safety
Safety Check List
Safety Decals
Typical Lifting Chart
Hydraulic tank breather filter change

Hydraulic oil filter change JS330LC

37.3MPa

39.2MPa

5000kg

C 9
8
Hydraulic oil filter clean B
Z1
7
6
5
4
3
Bm
C 2
kg 2 3 4 5 6 7 8 1
Z1 8010 6410 5450 4390 Z2 0
Z2 9320 8910 6590 5150 4220 -1
Z3 12660 8470 6740 -2
-3
Z1 8720 6450 5160 4420
-4
Z2 9390 8480 9120 6580 5140 4200
Z3 -5
Hydraulic oil level Z3

Z1
14270 11940

11580
9260

9420
6670

6620
5210

5080 4490 3690

-6
-7
Z2 5760 6400 9130 6850 5130 4190 3530
Z3 12010 10970 8740 6620 5160 10 9 8 7 6 5 4 3 2 1

Engine oil level

Fig 4.

1 Holding circuit pressure

Fuel tank level 2 Refer to operators manual before attempting to lift

3 Working circuit pressure

4 For complete swing of upper structure

Drain off water/sediment
5 Lift with bucket cylinder retracted

6 Mass of counterweight
When using hammer/crusher/
pulveriser 7 Track width indication

When using bio-degradeable oil

When using in wet or severe

conditions

2 - 14 9803/6540-1 2 - 14