Section 2 Section 2 i i Contents Page No. Safety Notices 14 Genoral Safoty a4 Operating Safety 341 Maintenance Safety a 803260 issue!Section 2 Section 2 1-4 Safety Notices In this publication and on the machine, there are safely notices. Each notice starts with a signal word, The signal word meanings are given below. A DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operaior (or others) could be kiled or seriously injured, A WARNING Denotes a hazard exists. f propor precautions are not taken, the operator (or othors) could be killed or seriously injured en AcauTion Denotes a reminder of safely practices. Failure to folow these safety practices could result in injury to the operator (or others) and possible damage to the machine. E29 1 ‘e097a260Section 2 Section 2 2-4 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 nat 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, Hf 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 ones General Safety AWwaRNING Decals You can be injured if you do not obey the decal safety insiructions. Keep decals clean. Replace unreadable of missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where = Awarning Care and Alertness Al the time you are working with of on the machine, take care and stay alert. Always be carelul. Alvays be alert for hazards, warning Clothing You can be injured it 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 overal, ear-protectors and industrial gloves. Koop cuffs fastened, Do not wear a necktie or scat. Keep long hair restrained. 2-4 A warnine Lifting Equipment You can be injured i you se fait lifting equipment. Make sure that liting equipment is in good condition. Make sure that lting tackte complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. 4 warnine Ralsed Attachments Raised attachments can fall and injure you. Do not walk oF work under raised attachments unless they are safely blocked. ‘e097a260Section 2 Section 2 3-4 3-4 Operating Safety A WARNING Machine Condition ‘Adofective machine ean injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are ‘completed before using the machine. Awarning Controls You or others can be kiled or seriously inured if you operate the contol levers from outside the cab. Operate the contro levers only when you are correctly seated inside the cab. Awarning Machine Limits Operating the machine beyond its design lmits can damage the machine, it can algo be dangerous. Do not operate the machine outside its limits, Do not tty to upgrade the machine performance with unapproved modifications. AWaRNING Engine/Steering Failure ifthe engine or steering fal, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. Awarning Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is sunning. Do not use the machine with the cover open. AWwaRNING Entering/Leaving ‘Always face the machine when entering and leaving the cab, Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. A WARNING Exhaust Gases Breathing the machine ethaust gases can harm and possibly kil you. Do not operate the machine in closed Spaces without making sure there is good ventilation. i possible, fi an exhaust extension. i you begin to feel {rowsy, stop the machine at once. Get out of the cab into fresh at. 4 WARNING ROPS/FOPS Structure The machine is fited with @ Roll Over Protection Structure (POPS) and a Faling Objects Protection Structure FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPSIFOPS, If the ROPSIFOPS has been in an accident, do not use the machine until the etucture has been renewed, Medications ahd repairs thal are not approved by the manulacurer may be dangerous “and wil invalidate’ the ROPS/FOPS cetiiction, 4 WaRNING Communtcations Bad communications can cause accidents. Keep people around you informed of whet you will be doing, If you willbe 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 A WARNING Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers. A DANGER 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 A warninc Powershift Transmission Do not change from a high gear to low gear (or instance, 4th fo tet) in one sudden movement whilst the machine is moving. Otherwise the machine wil rapidly decelerate, you ‘oF others could be kiled or seriously injured. When selecting Tower gears, allow the engine speed to drop before each gear change. ‘e097a260Section 2 Section 2 4-4 Maintenance Safety AWARNING Repairs Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. Awarning Modifications and Welding Non-approved modifications can cause injury and damage. Parts of the machine are made from east iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distrbutor for advice before ‘moditying the machine. A warninc Metal Spinters You can be injured by flying metal splinters when driving metal pins in or out. Use @ soll faced hammer ordi 10 remove and ft metal pins. Always wear safety glasses. Awarning Electrical Circuits Understand the electrical circuit before connecting or cisconnecting an electrical component. A wrong connection ‘can cause injury and/or damage. Awarnine Communications Bad communications can cause accidents. i two or more people are working on the machine, make sure each is ware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas: ‘examples of danger areas are: the rotating blades and belt fon the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. AWaRNING Petrol 1o not use petrol inthis machine, Do net mix petrol withthe close ual in storage tanks the petrol will ise fo the top and form flammable vapours. 44 A warnine Battory A battery with frozen electrolyte can explode if it is used or ‘charged. Do not use a machine with frozen battery. To help prevent the baltery from freezing, keep the battery fully charged. 4 WaRNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away trom the battery, Do not smoke close to the battery Make sure there is good ventilation in closed areas where batteries are being used or charged. Do no! check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. A warnine Battery Terminals ‘The machine is negatively earthed, Always connect the negative pole of the Battery to earth. ‘When connecting the battery, connect the earth () lead last, When disconnecting the battery, disconnect the earth (-) lead first Awarninc Hydraulic Fluid Fine jets of hydraulic uid at high pressure can penetrate the skin, Do not use your fingers to check for hydraulie fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic uid. Mt hydraulic fluid penetrates your skin, get medical help immediately A DANGER Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the ‘engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. ‘e097a260Section 2 Section 2 4-2 Maintenance Safety (cont'd) AWARNING Diesel Fuel Diese ful is flammable; keep naked flames away trom the machine. Do not emoke while refueling the machine or working on the engine. Do not refuel with the engine running. There could be a fre and injury you do not folow these precautions, AWARNING oil Ol is toxic. f you swallow any oi, do not induce vomiting seek medical advice. Used engine oll contains harmful contaminants which can cause skin cancer. Do not handle Used engine oll more than necessary. Always use barrier cream of wear gloves to prevent skin contact. Wash skin Contaminated with oll thoroughly in warm soapy water. Do not use petro, cies! fuel or parafin to clean your skin AwarNine Soft Ground AA machine can sink into soft ground. Never work under a machine on soft ground. AWwaRNinG ‘Tyres and Rims Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld o cut rims. Get a tyre/wheel specialist to do any repair work, Awarning Hot Coolant The cooling system is pressurised when the engin is hot Hot coolant can spray out when you remove the radiator cap. Let the system cool before removing the radiator cap To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. Awarning Always woar safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidently flying out. 4-2 Acaution Rams The efficiency of the rams wil be affected if they are not opt freo of soled dir. Clean din from around the rams regularly. When leaving or parking the machine, close all rams it possible to reduce the risk of weather corrosion. AcauTion Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents, Acaution “0' rings, Seals and Gaskets Badly fitted, damaged or rotted "0" rings, seals and gaskets can cause leakages and possible accidents. lenew Whenever cisturbed unless otherwise insttucted, Do not use ‘Triochioroethane or paint thinners near "O" rings and seals. A warnine Fes Wf your machine is equipped with a fre extinguisher, make sure it fs checked regulary. Keep itn the operator's cab tnt you need to use i Do not use water to put out a machine fire, you could spread an oil fire or get a shack from an elecrical fire. Use ‘carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use sel-contained breathing apparatus. A warnine Jacking, ‘A machine can roll off jacks and crush you unless the ‘heels have been chocked. Always chock the wheels at the ‘opposite end of the machine that is to be jacked, Do not work underneath a machine supported only by jacks. ‘Always support a jacked-up machine on axle stands before working undemeath it, ‘e097a260Section 2 Section 2 4-3 Maintenance Safety (cont'd) A WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: = Damaged end fittings = Chafed outer covers = Ballooned outer covers - Kinked or crushed hoses = Embedded armouring in outer covers = Displaced end fittings. A warnina Safety Strut Raised loader arms can drop suddenly and cause serious injury. Betore working under raised loader arms, fit the loader arm safety strut. Awarning A raised and badly supported machine can tall on you Position the machine on a frm, level surlace before raising fone end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to suppor the machine when working under it Disconnect the battery, to prevent the engine being started while you are beneath the machine, caves AWwarNING Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take afew weeks to dry completely. Keep flames away during the chying period Do not weld near the affected area during the drying period. Take the same precautions as for ol to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. warning Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the fengine. Chock both sides ofall four wheois Disconnect the battery, to prevent the engine being started while you are beneath the machine. one 4-3 A warnine To avoid burning, wear protective gloves when handling hot components, To protect your eyes, wear goggles when using a wire brush to clean components. wT A warnine JCB Extradig Dipper Lubricant JOB Extradig dipper lubrieart contains 1.53% lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant. Dispose of waste (rage etc.) in accordance with local regulations A WaRNING Fluoroolastomeric Materials Certain seals and gaskets (¢.g, crankshaft oll seal) on JCB, machines contain fluoroelastomerie materials such as Viton, Fluorel and’ Technoflon. Fluoroelastomerie mateials subjected to high temperatures can. produce highly corrosive hydrofluoric acid. THIS ACID GAN SEVERELY BURN New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charting) is ‘ound, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA, Used fluoroelastomeric components subjected to temperatures greater than 300° (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 Ensure that components have cooled then remove and place material into plastic bags. 2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary se wire woo! to remove burnt remains. 3 Thoroughly wash contaminated area with detergent and water. 4 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. 'W contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. ‘e097a260