jcb ROBOT 150 User manual

Service
Manual
ROBOT
150, 165
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER [phone]
PRINTED IN ENGLAND
Publication No. 9803/8500
General Information 1
Care & Safety 2
Routine Maintenance 3
Attachments A
Body & Framework B
Electrics C
Controls D
Hydraulics E
Transmission F
Brakes G
Engine K
R

Introduction
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.
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. Finally, please remember above all
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1=General Information - includes torque settings and service tools.
2=Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3=Routine Maintenance - includes service schedules and recommended lubricants for all the
machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A=Attachments
B=Body & Framework ...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
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.
With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.
9803/8500 Issue 1

i
Contents Page No.
Identifying your Machine 1 - 1
Torque Settings 2 - 1
Service Tools
- Numerical List 3 - 1
- Electrics 4 - 1
- Hydraulics 4 - 2
Sealing and Retaining Compounds 5 - 1
Section 1 General Information
9803/8500
Section 1
i
Issue 1

1 - 1
The serial number of the chassis, engine, lift arm and
hydraulic pump unit positively identify the type of JCB Skid
Steer Loader you have.
Machine Identification Plate
The machine identification plate Ais located as shown. It is
stamped with the serial numbers of the major individual units.
Typical Vehicle Identification Number (VIN)
SLP 165 S B V E 677001
World Manufacturer Identification
Machine Model
Machine Type (S = Standard, H = High-flow)
Build Type (A = Canopy, B = Cab)
Year of Manufacture:
T = 1996 1 = 2001
V = 1997 2 = 2002
W = 1998 3 = 2003
X = 1999 4 = 2004
Y = 2000 5 = 2005
Manufacturer Location (E = England)
Product Identification Number (PIN)
Section 1 General Information
9803/8500
Section 1
1 - 1
Issue 5
Identifying your Machine
AA
S173720
CONSTRUCTOR MADE IN UK
J.C.BAMFORD EXCAVATORS LTD.
ROCESTER, STAFFS, ENGLAND.
R
Vehicle Identification No. Product Identification No.
ENGINE SERIAL No. WEIGHT
PUMP SERIAL No. YEAR OF MANUFACTURE
MODEL 80/1269/EEC MODEL 80/1269/EEC
POWER KW R.P.M. POWER KW R.P.M.
150
165
165 HF
1CX
1CX HF
185
185 HF
35
35
35
35
35
52
52
2800
2800
2800
2800
2800
2200
2200
817/04437
11223344556677
11
22
33
44
55
66
77

1 - 2
Unit Identification
The engine serial number on XUD engines is stamped on a
machined area Bon the top of the cylinder block. On JCB
Diesel engines the number is stamped on a label Gon the
left side of the cylinder block.
The chassis serial number is stamped on the front edge of
the right hand mudguard as shown at C. On early machines
the serial number is stamped on the right hand side of the
machine as shown at F.
The lift arm serial number is stamped on the rear of the lift
arm as shown at D.
The hydraulic pump unit serial number is stamped on a plate
on the top of the pump at E.
If any of the above units are replaced with new ones, the
relevant serial number on the Machine Identification Plate will
be superseded. Either stamp the plate with the new number
or stamp out the old number.
Left Side, Right Side
In this manual, 'left' Xand 'right' Ymean your left and right
when you are seated correctly in the machine.
Section 1 General Information
9803/8500
Section 1
1 - 2
Issue 2*
Identifying your Machine
Y
XS173660
BB
DD
S173730
S173750
S255430
GG
EE
S173760
CC
FF
S173742
*

2 - 1
Section 1 General Information
9803/8500
Section 1
2 - 1
Issue 2*
Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
1/4(6.3) 7/16 14 1.4 10
5/16 (7.9) 1/228 2.8 20
3/8(9.5) 9/16 49 5.0 36
7/16 (11.1) 5/878 8.0 58
1/2(12.7) 3/4117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8(15.9) 15/16 238 24.3 175
3/4(19.0) 11/8407 41.5 300
7/8(22.2) 15/16 650 66.3 480
1 (25.4) 11/2970 99.0 715
11/4(31.7) 17/81940 198.0 1430
11/2(38.1) 21/43390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
*

3 - 1
Numerical List
Page No.
1406/0011 Bonded Washer 4 - 3
1406/0018 Bonded Washer 4 - 3
1406/0021 Bonded Washer 4 - 2/4 - 3
1406/0029 Bonded Washer 4 - 3
1604/0003 Adapter 4 - 3
1604/0004 Adapter 4 - 3
1604/0006 Adapter 4 - 2/4 - 3
1606/0003 Adapter 4 - 3
1606/0004 Adapter 4 - 3
1606/0007 Adapter 4 - 3
1606/0008 Adapter 4 - 3
1606/0009 Adapter 4 - 3
1612/0006 Adapter 4 - 2
4101/0251 Threadlocker and Sealer 5 - 1
4101/0451 Threadlocker 5 - 1
4101/0552 Threadlocker and Sealer (High Strength)5 - 1
4101/0651 Retainer (High Strength) 5 - 1
4102/0551 High Strength Threadlocker 5 - 1
4102/1201 Multi-Gasket 5 - 1
4104/0251 Activator (Aerosol) 5 - 1
4104/0253 Activator (Bottle) 5 - 1
4104/1557 JCB Cleaner/Degreaser 5 - 1
816/00189 Blanking Cap 4 - 4
816/00190 Blanking Cap 4 - 4
816/00193 Blanking Cap 4 - 4
816/00196 Blanking Cap 4 - 4
816/00197 Blanking Cap 4 - 4
816/00294 Blanking Cap 4 - 4
816/15118 Pressure Test Adapter 4 - 2
816/20008 Adapter 4 - 2
816/50043 'T' Adapter 4 - 4
816/55038 Pressure Test 'T' Adapter 4 - 2
816/55040 Pressure Test 'T' Adapter 4 - 2
816/60096 'T' Adapter 4 - 4
892/00047 'T' Adapter 4 - 4
892/00048 'T' Adapter 4 - 4
892/00055 Blanking Plug 4 - 4
892/00056 Blanking Plug 4 - 4
892/00057 Blanking Plug 4 - 4
892/00059 Blanking Plug 4 - 4
892/00060 Blanking Plug 4 - 4
892/00074 Female Connector 4 - 4
892/00075 Female Connector 4 - 4
892/00077 Female Connector 4 - 4
892/00137 Hose 4 - 3
892/00223 Hand Pump 4 - 3
892/00252 A.R.V Test Block - Husco 4 - 3
892/00253 Pressure Test Kit 4 - 2
892/00255 Pressure Test Adapter 4 - 2
892/00256 Pressure Test Adapter 4 - 2
892/00257 Pressure Test Adapter 4 - 2
892/00258 Pressure Test Adapter 4 - 2
892/00259 Pressure Test Adapter 4 - 2
892/00260 Pressure Test Adapter 4 - 2
892/00261 Pressure Test Adapter 4 - 2
892/00262 Pressure Test 'T' Adapter 4 - 2/4 - 3
892/00263 Pressure Test 'T' Adapter 4 - 2
892/00264 Pressure Test 'T' Adapter 4 - 2
892/00265 Pressure Test 'T' Adapter 4 - 2
Page No.
892/00268 Flow Monitoring Unit 4 - 2
892/00269 Sensor Head 4 - 2
892/00270 Load Valve 4 - 2
892/00271 Adapter 4 - 2
892/00272 Adapter 4 - 2
892/00274 Adapter 4 - 3
892/00275 Adapter 4 - 2
892/00276 Adapter 4 - 2
892/00277 Adapter 4 - 2
892/00278 Gauge 4 - 3
892/00279 Gauge 4 - 3
892/00281 AVO Meter 4 - 1
892/00282 Shunt 4 - 1
892/00283 Tool Kit Case 4 - 1
892/00284 Tachometer 4 - 1
892/00285 Hydraulic Oil Temperature Probe 4 - 1
892/00286 Surface Temperature Probe 4 - 1
892/00706 Test Probe 4 - 3
892/00858 Pump Support Bracket 4 - 3
892/00923 A.R.V Test Block - Commercial Hyd. 4 - 3
992/09300 Spanner 4 - 3
992/09400 Spanner 4 - 3
992/09500 Spanner 4 - 3
992/09600 Spanner 4 - 3
993/68100 Slide Hammer 4 - 4
993/85700 Battery Tester 4 - 1
993/99510 Half Moon Spanner 4 - 4
The following parts are replacement items for kits and would
normally be included in the kit numbers quoted above.
Replacement items for kit no. 892/00253
892/00201 Replacement Gauge 4 - 2
892/00202 Replacement Gauge 4 - 2
892/00203 Replacement Gauge 4 - 2
892/00254 Replacement Hose 4 - 2
Section 1 General Information
9803/8500
Section 1
3 - 1
Issue 8*
Service Tools
*
*
*
*
*
*
*
*

4 - 1
Section 1 General Information
9803/8500
Section 1
4 - 1
Issue 2*
Service Tools
Section C - Electrics
AVO Test Kit
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
* 993/85700 Battery Tester
188230
239510

Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSPP x Test Point
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Flow Test Equipment
892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP
4 - 2
Section E - Hydraulics
Section 1 General Information
9803/8500
Section 1
4 - 2
Issue 2*
Service Tools
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)
892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254 Replacement Hose
188120
*
200140
188150
188130

Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
4 - 3
Section E - Hydraulics
Bonded Washers
1406/0011 1/4 in BSP
1406/0018 1/2 in BSP
1406/0021 3/4 in BSP
1406/0029 1.1/4 in BSP
Section 1 General Information
9803/8500
Section 1
4 - 3
Issue 5*
Service Tools
Hexagon Spanners for Ram Pistons and End Caps
992/09300 55 mm A/F
992/09400 65 mm A/F
992/09500 75 mm A/F
992/09600 85 mm A/F
Male Adapters - BSP x BSP
1606/0003 3/8 in x 1/4 in
1604/0003 3/8 in x 3/8 in
1606/0004 1/2 in x 1/4 in
1606/0007 1/2 in x 3/8 in
1604/0004 1/2 in x 1/2 in
1606/0008 3/4 in x 3/8 in
1606/0009 3/4 in x 1/2 in
1604/0006 3/4 in x 3/4 in
193850 188140
193860
193930
892/00252 Test Block for A. R. V. - Husco valves
892/00923 Test Block for A. R. V.
- Commercial Hydraulic valves
*
*
892/00858 Pump support bracket - for engine removal.
A215880
220840
S270650

4 - 4
Female Cone Blanking Plug
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP'T'
* 993/68100 Slide Hammer
993/99510 Half Moon Spanner
Section 1 General Information
9803/8500
Section 1
4 - 4
Issue 2*
Service Tools
Female Connectors
892/00074 3/8 in BSP x 3/8 in BSP
892/00075 1/2 in BSP x 1/2 in BSP
892/00077 3/4 in BSP x 3/4 in BSP
Male Cone Blanking Plug
816/00294 1/4 in BSP
816/00189 3/8 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP
'T' Adapters
892/00047 3/8 in BSP (A) x 1/4 in BSP (B)
892/00048 1/2 in BSP (A) x 1/4 in BSP (B)
816/50043 3/4 in BSP (A) x 1/4 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
Section E - Hydraulics
193870 193880
193890 193900
193910
193920

5 - 1
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1201
JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. 4102/0551
JCB Retainer (High Strength) For retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and
retaining nuts, bolts, and screws up to 50 mm dia.,
and for hydraulic fittings up to 25 mm dia. 4101/0251
JCB Threadlocker & Sealer A medium to high strength locking fluid for retention and
(High Strength) sealing of ram piston heads. 4101/0552
JCB Threadlocker A locking fluid for use on threads larger than 50 mm dia. 4101/0451
JCB Activator A cleaning primer which speeds the curing rate of
anaerobic products. 4104/0251 Aerosol
4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic
adhesives and sealants. 4104/1557 Aerosol
The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with
effect from January 1997 (see MI 563/H, 507/HA, 511/E). The list above has been changed accordingly.
References to these products on subsequent pages in this service manual will be progressively updated but for convenience a
cross reference table is shown below.
Old Description Old Part Number New Description New Part Number
JCB High Strength Threadlocker 4102/0502 JCB High Strength Threadlocker 4102/0551
JCB High Strength Retainer 4101/0602 JCB Retainer (High Strength) 4101/0651
JCB Lock & Seal 4101/0202 JCB Threadlocker & Sealer 4101/0251
Loctite 243 4101/1101 Use 4101/0251
Loctite 262 4101/0502 JCB Threadlocker & Sealer (High Strength) 4101/0552
Loctite 932 4101/0402 JCB Threadlocker 4101/0451
Loctite Activator N 4104/0101 Aerosol JCB Activator 4104/0251
4104/0102 Bottle 4104/0253
JCB Cleaner & Degreaser 4104/1538 Aerosol JCB Cleaner/Degreaser 4104/1557
Section 1 General Information
9803/8500
Section 1
5 - 1
Issue 5
Sealing and Retaining Compounds

i
Contents Page No.
Safety Notices 1 - 1
General Safety 2 - 1
Operating Safety 3 - 1
Maintenance Safety 4 - 1
Safety Decals 5 - 1
Section 2 Care and Safety
9803/8500
Section 2
i
Issue 1

1 - 1
Section 2 Care and Safety
9803/8500
Section 2
1 - 1
Issue 1
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.
!!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.
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
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
General Safety
!!WARNING
Decals
You can be injured if you do not obey the decal safety
instructions. Keep decals clean. Replace unreadable or
missing decals with new ones before operating the machine.
Make sure replacement parts include warning decals where
necessary.
INT-1-3-4
!!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.
INT-1-3-5
!!WARNING
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.
INT-1-3-6
!!WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is strong
enough for the job.
INT-1-3-7
!!WARNING
Raised Attachments
Raised attachments can fall and injure you. Do not walk or
work under raised attachments unless they are safely
blocked.
INT-1-3-8
Section 2 Care and Safety
9803/8500
Section 2
2 - 1
Issue 2

3 - 1
Operating Safety
!!WARNING
Controls
You or others can be killed or seriously injured if you operate
the control levers from outside the cab. Operate the control
levers only when you are correctly seated inside the cab.
INT-2-1-3
!!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-2-1-4
!!WARNING
Entering/Leaving
When entering and leaving the cab, use the step and
handrails. Make sure the step, handrails and your boot soles
are clean and dry. Do not jump from the machine. Do not use
the machine controls or Safety Restraint Bar as handholds,
use only the handrails.
3-1-1-1
!!WARNING
Engine
The engine has rotating parts. Do not open the engine cover
while the engine is running. Do not use the machine with the
cover open.
INT-2-1-6
!!WARNING
ROPS/FOPS Structure
The machine is fitted with a Roll Over Protection Structure
(ROPS) and a Falling Objects Protection Structure (FOPS).
You could be killed or seriously injured if you operate the
machine with a damaged or missing ROPS/FOPS. If the
ROPS/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.
INT-2-1-9/3
!!WARNING
Seat Belts
The ROPS/FOPS cab is designed to give you protection in
an accident. If you do not wear your seat belt, you could be
thrown around inside the cab or 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.
2-2-1-9
!!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. Get out of the cab into fresh air.
INT-2-1-10
!!WARNING
Passengers
Passengers in or on the machine can cause accidents. The
JCB Skid Steer Loader is a one man machine. Do not carry
passengers.
INT-2-2-2
!!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-2-2-3
!!WARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramp 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. Always reverse up a ramp if
unloaded, travel forwards if loaded.
3-1-1-3/1
!!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.
INT-2-2-10
!!WARNING
Attachments
Use only JCB approved attachments. Non-approved
attachments, modified to fit the Skid Steer Loader, could
cause damage to the machine, and/or make it unsafe. The
use of non-approved attachments could invalidate your
warranty.
3-1-2-1
Section 2 Care and Safety
9803/8500
Section 2
3 - 1
Issue 2

4 - 1
Maintenance Safety
!!WARNING
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.
GEN-1-5
!!WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
!!WARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury or damage.
iNT3-1-4
!!WARNING
Communications
Bad communications can cause accidents. If two or more
people are working on the machine, make sure each is
aware 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
on 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.
INT-3-1-5
!!WARNING
Petrol
Do not use petrol in this machine. Do not mix petrol with the
diesel fuel; in storage tanks the petrol will rise to the top and
form flammable vapours.
INT-3-1-6
!!WARNING
Battery
A battery with frozen electrolyte can explode if it is used or
charged. Do not use a machine with a frozen battery. To help
prevent the battery from freezing, keep the battery fully
charged.
INT-3-1-7
!!WARNING
Battery Gases
Batteries give off explosive gases. Keep flames and sparks
away from 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 not check the
battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8
!!WARNING
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.
INT-3-1-9
!!WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic 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 fluid. If hydraulic fluid
penetrates your skin, get medical help immediately.
INT-3-1-10/1
!!WARNING
Hydraulic Pressure
It is not possible to vent all residual pressure. Loosen the
connection one full turn and allow the pressure to dissipate.
Keep face and hands well clear of pressurised hydraulic oil
and wear protective glasses.
HYD 4-3
!!DANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not breathe the
gases given off by the battery. Keep the electrolyte away
from your clothes, skin, mouth and eyes. Wear safety
glasses. See Battery in MAINTENANCE section for First Aid
treatment.
INT-3-2-1/2
!!WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine running.
There could be a fire or injury if you do not follow these
precautions.
INT-3-2-2
Section 2 Care and Safety
9803/8500
Section 2
4 - 1
Issue 2

4 - 2
Maintenance Safety (cont'd)
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Tyres and Rims
Over-inflated or over-heated tyres can explode. Follow the
instructions in this manual for inflating the tyres. Do not weld
or cut rims. Get a tyre/wheel specialist to do any repair work.
INT-3-2-6
!!WARNING
Fires
If your machine is equipped with a fire extinguisher, make
sure it is checked regularly. Keep it in the operator's cab 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-3-2-7/1
!!WARNING
Hot Coolant
The cooling system is pressurised when the engine 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 steam
pressure escape, then remove the cap.
INT-3-2-9
!!CAUTION
Rams
The efficiency of the rams will be affected if they are not kept
free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
!!CAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!!CAUTION
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!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.
INT-3-3-2
!!WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This will
protect against eye injury from components accidentally
flying out.
GEN-6-2
Section 2 Care and Safety
9803/8500
Section 2
4 - 2
Issue 2

5 - 1
Safety Decals
!!WARNING
Decals on the machine warn you of particular hazards. Each
decal is attached close to a part of the machine where there
is a possible hazard. Read and make sure you understand
the safety message before you work with or on that part of
the machine.
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment points are
shown on the following pages. 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
!!WARNING
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
Section 2 Care and Safety
9803/8500
Section 2
5 - 1
Issue 2