jcb 516-40 TIER 3 User manual

OPERATOR’S MANUAL
This manual should always stay with the machine
9821/9750-2 09/2015
ENGLISH
LOADALL
516-40 AND
516-40 AGRI
TIER 3

THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
LOADALL - 516-40 AND 516-40 AGRI-TIER 3
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.
A4-5-Loadall - Printed In England
Dear JCB Customer
Even if you have operated this type of equipment before,
it is very important that your new machines operations and
functions are explained to you by a JCB Dealer
Representative following delivery of your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your new
product.
Please contact your local JCB dealer if the Installation
Form has not yet been completed with you.
Your Local JCB Dealer is:
ENGLISH - 9821/9750 - ISSUE 2 - SEPTEMBER 2015
OPERATOR MANUAL
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0 0
9821/9750
Notes:
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Page No.Contents
i i
Safety Notices
Important Information ....................................................................................1
The Operator Manual ...............................................................................1
Safety Warnings .......................................................................................1
Introduction
About This Manual .........................................................................................3
Name and Address of Manufacturer ........................................................3
Product Compliance .................................................................................3
Machine Model and Serial Number ..........................................................3
Using this Manual .....................................................................................3
Left Side, Right Side .................................................................................4
Cab/Canopy .............................................................................................4
Cross References .....................................................................................4
Machine Description ......................................................................................5
The JCB 516-40 .......................................................................................5
Intended Use ............................................................................................5
Component Location ................................................................................5
Safety Check List ...........................................................................................6
Safety - Yours and Others ........................................................................6
General Safety .........................................................................................6
Operating Safety ......................................................................................8
Maintenance Safety ................................................................................12
Safety Labels ...............................................................................................17
Introduction .............................................................................................17
Safety Label Identification ......................................................................18
Part Numbers and Descriptions .............................................................18
Identifying Your Machine .............................................................................21
Machine Identification Plate ...................................................................21
Typical Product Identification Number .................................................21
Component Identification Plates .............................................................22
Typical Engine Identification Number ..................................................22
Emission Control Information ...............................................................22
ROPS Data Plate .................................................................................22
FOPS Data Plate .................................................................................24
Machine Security .........................................................................................25
Introduction .............................................................................................25
JCB Plantguard ......................................................................................25
Construction Equipment Security And Registration Scheme (CESAR) .25
Operation
Introduction ..................................................................................................27
Before Entering the Cab ..............................................................................28
Entering and Leaving the Cab .....................................................................29
Emergency Exit ......................................................................................30
Doors and Windows ....................................................................................31
Opening and Closing the Doors .............................................................31
Opening and Closing the Door Upper Section .......................................32
Door Catch ...........................................................................................32
Visibility Aids ................................................................................................33
Mirrors and Adjustment ..........................................................................33
Introduction ..........................................................................................33
Mirrors ..................................................................................................34
Visibility Diagrams ................................................................................35
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Contents
ii ii
Page No.Contents
Seat Controls ...............................................................................................39
Introduction .............................................................................................39
Operators Seat .......................................................................................39
Seat Belt ......................................................................................................40
Inertia Reel Seat Belt .............................................................................40
Fasten the Seat Belt ............................................................................40
Check the Seat Belt is Operating Correctly .........................................40
Release the Seat Belt ..........................................................................40
Cab Layouts ................................................................................................41
Three Lever Control ...............................................................................41
Component Key ...................................................................................41
Single Lever Control (Optional) ..............................................................42
Component Key ...................................................................................42
Drive Controls, Switches and Instrument Panel ..........................................43
Drive Controls - Manual Lever machines ...............................................43
Steering Wheel ....................................................................................43
Accelerator Pedal ................................................................................43
Brake/Inching Pedal .............................................................................43
Forward/Reverse Switch ......................................................................43
Park Brake Lever .................................................................................44
Park brake Warning .............................................................................44
Horn .....................................................................................................45
Drive Controls - Single Lever Machines (Optional) ................................46
Steering Wheel ....................................................................................46
Accelerator Pedal ................................................................................46
Brake/Inching Pedal .............................................................................46
Forward/Reverse Switch ......................................................................46
Park Brake Lever .................................................................................46
Varispeed Control (Option) ..................................................................47
Horn .....................................................................................................47
Switches .................................................................................................48
Console Panel Switches ......................................................................48
Column Switches .................................................................................51
Starter Switch .......................................................................................51
Cab Interior Light .................................................................................52
Roof-Mounted Wiper ............................................................................52
Instrument Panel ....................................................................................53
Digital LCD Fuel Gauge .......................................................................54
Indicator Lights ....................................................................................54
Blink Codes - Boom Extend - Retract ..................................................55
Blink Codes - Auxiliary Warning Light ..................................................55
Warning Lights .....................................................................................56
Heater Controls ......................................................................................58
Heater ..................................................................................................58
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Contents
iii iii
Page No.Contents
Operating Levers .........................................................................................59
Introduction .............................................................................................59
Boom and Carriage Controls - Manual Lever Machines (Option) ..........60
Introduction ..........................................................................................60
Raise Boom/Lower Boom ....................................................................60
Tilt Carriage Back/Forward (Crowd/Dump) ..........................................60
Extend Boom/Retract Boom ................................................................61
Boom and Carriage Controls - Single Lever Machines (Option) ............62
Overview ..............................................................................................62
Auxiliary Controls - Manual Lever Machines (If fitted) ............................63
Auxiliary Controls - Single Lever Machines ............................................63
Introduction ..........................................................................................63
Auxiliary (Constant Flow Mode) ...........................................................63
Safety Equipment ........................................................................................65
Load Charts ............................................................................................65
Introduction to Load Charts .................................................................65
Using the Load Charts .........................................................................65
Longitudinal Load Moment Indicator (LLMI) ...........................................67
Introduction ..........................................................................................67
Checking the Indicator .........................................................................68
Setting the Volume and Brightness ......................................................69
Diagnostic Fault Codes ........................................................................70
LLMI with Longitudinal Load Moment Control ........................................71
Introduction ..........................................................................................71
Load Control Mode ..............................................................................73
Emergency Override Function .............................................................74
Warm Up Procedure ............................................................................74
Daily Functional Check ........................................................................75
Inclinometer ............................................................................................76
Fire Extinguisher (if fitted) ......................................................................76
Operation .............................................................................................76
Beacon ...................................................................................................77
Before Starting the Engine ...........................................................................78
Starting the Engine ......................................................................................80
Preparing the Machine for Travel ................................................................82
Introduction .............................................................................................82
Preparing for Road Travel ......................................................................82
Preparing for Site Travel .........................................................................84
Getting the Machine Moving ........................................................................85
Operating Practices ................................................................................85
Operating Procedure ..............................................................................86
Stopping and Parking the Machine ..............................................................87
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Contents
iv iv
Page No.Contents
Working with the Machine ...........................................................................89
Operating Practices and Site Safety ......................................................89
Clothing and Safety Equipment ..............................................................89
Danger Zone ..........................................................................................89
Working with the Boom ..........................................................................90
Introduction ..........................................................................................90
Risk Assessment .................................................................................91
Lifting and Loading Operations ............................................................92
Fork Ratings ........................................................................................93
Handling Palleted Loads ......................................................................94
Handling Bales .....................................................................................95
Handling Uneven Loads ......................................................................96
Stacking Loads ....................................................................................97
Filling a Shovel ....................................................................................98
Loading a Truck ...................................................................................99
Use of Machines on Gradients or Slopes ...............................................99
Driving Up and Down Gradients ..........................................................99
Driving Across Gradients ...................................................................100
Lifting Operations on Gradients .........................................................101
Operating Environment ..............................................................................102
Operating in Low Temperatures ...........................................................102
Operating in High Temperatures ..........................................................102
Refuelling the Machine ..............................................................................103
Low Fuel Levels ...................................................................................103
Filling the Tank .....................................................................................103
Moving a Disabled Machine ......................................................................105
Transporting the Machine ..........................................................................106
Lifting the Machine ....................................................................................108
Introduction ...........................................................................................108
Preparing the Machine .........................................................................108
Lifting the Machine ...............................................................................109
Storage of the Machine ............................................................................. 110
Introduction ........................................................................................... 110
Storage Area ........................................................................................110
Prepare the Machine for Storage .........................................................110
Put the Machine into Storage ...............................................................110
During Storage .....................................................................................110
Take the Machine Out of Storage ......................................................... 111
Routine Maintenance
Service Requirements ...............................................................................113
Fit for Purpose Tests for Lifting Equipment ...........................................113
Obtaining Replacement Parts ...............................................................113
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Contents
v v
Page No.Contents
Health and Safety ...................................................................................... 114
Lubricants .............................................................................................114
Introduction ........................................................................................114
Hygiene ..............................................................................................114
Storage ..............................................................................................114
Waste Disposal ..................................................................................114
Handling ............................................................................................. 114
First Aid - Oil ...................................................................................... 115
Spillage ..............................................................................................115
Fires ...................................................................................................115
Battery ..................................................................................................116
Warning Symbols ............................................................................... 117
First Aid - Electrolyte ..........................................................................117
Service Schedules .....................................................................................118
Introduction ........................................................................................... 118
How to Use the Service Schedules ...................................................... 118
Calendar Equivalents ...........................................................................118
Pre-start Cold Checks, Service Points and Fluid Levels ......................119
Functional Test and Final Inspection ....................................................122
Fluids, Lubricants and Capacities ..............................................................124
Specifications .......................................................................................124
Fuels .....................................................................................................125
Acceptable and Unacceptable Fuels .................................................125
Fuels for Low Temperatures ..............................................................125
Biodiesel Fuel ....................................................................................125
Coolant Mixtures ..................................................................................127
Tools ..........................................................................................................128
Toolbox .................................................................................................128
Carrying Tools onto the Machine ..........................................................128
Prepare the Machine for Maintenance ......................................................129
Introduction ...........................................................................................129
How to Make the Machine Safe (Boom Lowered) ................................129
How to Make the Machine Safe (Boom Lifted) .....................................130
Installing the Maintenance Strut .........................................................130
Removing the Maintenance Strut .......................................................131
Using a Jack to Lift the Machine ..........................................................131
Cleaning the Machine ................................................................................134
Introduction ...........................................................................................134
Detergents .........................................................................................134
Pressure Washing and Steam Cleaning ............................................134
Preparing the Machine for Cleaning .....................................................135
Cleaning the Machine ...........................................................................135
Fan Reverse (if fitted) ...........................................................................138
Checking For Damage ...............................................................................139
Checking the ROPS/FOPS ..................................................................139
Greasing ....................................................................................................141
Preparing the Machine for Greasing ....................................................142
Greasing Sequence ..............................................................................142
Grease Points .......................................................................................143
Boom Pivot Grease Points .................................................................143
Front Steering Linkage Grease Points ...............................................144
Rear Steering Linkage Grease Points ...............................................144
Rear Axle Pivot Grease Point ............................................................145
Wear Pad Runways and Bonnet Hinge Points ..................................145
Extension Ram Pivot .........................................................................146
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Contents
vi vi
Page No.Contents
Oiling .........................................................................................................147
Access Panels ...........................................................................................148
Introduction ...........................................................................................148
Engine Cover ........................................................................................149
Maintenance Position ........................................................................149
Operation Position .............................................................................149
Engine Side Panel ................................................................................149
Maintenance Position ........................................................................149
Operation Position .............................................................................150
Rear Engine Guard ..............................................................................151
Maintenance Position ........................................................................151
Operation Position .............................................................................151
Underfloor Cover ..................................................................................152
Maintenance Position ........................................................................152
Operation Position .............................................................................152
Hydraulic Tank Cover ...........................................................................152
Maintenance Position ........................................................................152
Operation Position .............................................................................153
Operators Seat Base ............................................................................154
Maintenance Position ........................................................................154
Operation Position .............................................................................154
Rear Wheel Arch Panels ......................................................................155
Maintenance Position ........................................................................155
Operation Position .............................................................................155
Left Instrument Panel ...........................................................................155
Maintenance Position ........................................................................155
Operation Position .............................................................................155
Right Cab Panel ...................................................................................156
Maintenance Position ........................................................................156
Operation Position .............................................................................156
Air Conditioning (If Fitted) ..........................................................................157
Service Checks ....................................................................................157
Off-Season Operation ........................................................................157
Cab Heater Filter .......................................................................................158
Replacing the Cab Heater Filter ...........................................................158
Brakes .......................................................................................................159
Park Brake ............................................................................................159
Introduction ........................................................................................159
Testing the Park Brake .......................................................................159
Park Brake Adjustment up to sn 1769015 .........................................161
Park Brake Adjustment from sn 1769016 ..........................................162
Foot Brake ............................................................................................162
Checking the Foot Brake Fluid Level .................................................162
Checking the Brake Shoe Condition ..................................................164
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Contents
vii vii
Page No.Contents
Electrical System .......................................................................................165
Introduction ...........................................................................................165
Battery ..................................................................................................165
Battery Disconnection/Connection .....................................................165
Checking the Electrolyte Level ..........................................................165
Battery Isolator ...................................................................................166
Jump Starting the Engine .....................................................................167
Fuses ....................................................................................................169
Introduction ........................................................................................169
Primary Fuses ....................................................................................170
Secondary Fuses ...............................................................................171
Relays ..................................................................................................173
LLMC Components ..............................................................................174
Engine .......................................................................................................175
Component Locations ..........................................................................175
Oil and Filter .........................................................................................175
Introduction ........................................................................................175
Checking the Oil Level .......................................................................176
Changing the Oil and Filter ................................................................177
Cooling System ....................................................................................179
Introduction ........................................................................................179
Checking the Coolant Level ...............................................................179
Changing the Coolant ........................................................................180
Alternator Drive Belt .............................................................................181
Adjusting the Alternator Drive Belt .....................................................181
Alternator Belt Replacement ..............................................................181
Compressor Drive Belt (if fitted) ...........................................................183
Adjusting the Compressor Drive Belt .................................................183
Compressor Belt Replacement ..........................................................184
Hydraulic Service Pump Drive Belt ......................................................185
Adjusting the Service Pump Drive Belt ..............................................185
Service Pump Drive Belt Replacement ..............................................186
Air Filter ................................................................................................186
Cleaning the Filter and Changing the Elements ................................186
Cleaning the Air Filter Dust Valve ......................................................187
Fuel System ...............................................................................................188
Introduction ...........................................................................................188
Fuel Filter .............................................................................................189
Draining the Filter ..............................................................................189
Changing the Fuel Filter Element ......................................................189
Bleeding the Fuel System ....................................................................190
Hydraulic System .......................................................................................192
Introduction ...........................................................................................192
Release the Hydraulic Pressure ...........................................................192
Oil and Filter .........................................................................................193
Checking the Fluid Level ...................................................................193
Changing the Filter Element ..............................................................194
Filling the Hydraulic System ..............................................................194
Changing the Hydraulic Breather Cap ..................................................194
Hose Burst Protection Valves ...............................................................196
Checking the Hose Burst Protection Valves ......................................196
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Contents
viii viii
Page No.Contents
Tyres and Wheels ......................................................................................197
Tyre Inflation .........................................................................................197
Introduction ........................................................................................197
Procedure ..........................................................................................197
Tyre Wear .............................................................................................198
Changing A Wheel ...............................................................................198
Checking the Wheel Nut Torques .........................................................199
Wheel Alignment .......................................................................................200
Steer Phasing Adjustment ....................................................................200
Wear Pads .................................................................................................201
Windscreen Washer Reservoir ..................................................................202
Fire Extinguisher (if fitted) ..........................................................................203
Checking the Fire Extinguisher ............................................................203
Optional Attachments
Introduction ................................................................................................205
Attachments for your Machine ...................................................................206
Connecting/Disconnecting Hydraulic Hoses ..............................................207
Introduction ...........................................................................................207
Connecting the Hydraulic Hoses ..........................................................207
Disconnecting the Hydraulic Hoses ......................................................208
Quick Release Couplings .....................................................................209
Essential Do's ....................................................................................209
Essential Don'ts .................................................................................209
Connecting Quick Release Couplings ...............................................210
Disconnecting Quick Release Couplings ...........................................210
Quickhitch ..................................................................................................211
Introduction ........................................................................................... 211
Installing Attachments ..........................................................................211
Removing Attachments ........................................................................212
Tool Carrier Hitch .......................................................................................213
Installing Attachments ..........................................................................213
Removing Attachments ........................................................................214
Hydraulic Tool Carrier Hitch .......................................................................216
Installing Attachments ..........................................................................216
Removing Attachments ........................................................................217
Pallet Forks ................................................................................................219
Safety ...................................................................................................219
Changing/Repositioning the Forks .......................................................219
Road Travel ..........................................................................................220
Daily Maintenance ................................................................................220
6-in-1 Shovel .............................................................................................221
Safety ...................................................................................................221
Preparing for Travel ..............................................................................221
Control ..................................................................................................221
Operation ..............................................................................................221
Loading and Digging ..........................................................................221
Grabbing ............................................................................................221
Grading ..............................................................................................222
Dozing ................................................................................................222
Spreading ...........................................................................................223
Daily Maintenance ................................................................................224
Work Platforms ..........................................................................................225

Contents
ix ix
Page No.Contents
Specifications
Static Dimensions ......................................................................................227
Performance Dimensions ..........................................................................228
Load Charts ..........................................................................................228
Lift Performance ...................................................................................230
Loader Performance .............................................................................231
Maximum Wading Depth ......................................................................232
Engine ..................................................................................................232
Operating Angle .................................................................................232
Tyre Sizes and Pressures ..........................................................................233
Introduction ...........................................................................................233
Specifications .......................................................................................234
Noise Data .................................................................................................235
Introduction ...........................................................................................235
Noise Technical Information .................................................................235
Vibration Data ............................................................................................236
Introduction ...........................................................................................236
Minimising Exposure to Vibration .......................................................236
516-40 ..................................................................................................237
Machine Operating Duties .................................................................237
Vibration Technical Information ............................................................237
Warranty Information
Machine Service Record Sheet .................................................................239
Registration Information ............................................................................241
European Community Standards
EC Declaration of Conformity ....................................................................243
Introduction ...........................................................................................243

Contents
x x
Page No.Contents

1 1
9821-9750-2
Safety Notices
Important Information
T1-042
The Operator Manual
!MWARNING
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.
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.
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.
Safety Warnings
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
This safety alert system identifies
important safety messages in this
manual. When you see this symbol, be
alert, your safety is involved, carefully
read the message that follows, and inform
other operators.

Safety Notices
Important Information
2 2
9821-9750-2
Page left intentionally blank

3 3
9821-9750-2
Introduction
About This Manual
Name and Address of Manufacturer
Product Compliance
T1-055
Your JCB machine was designed to comply with the laws
and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets,
laws and regulations exist that require the owner to
maintain the machine at a level of compliance relevant to
the machine when first produced. Even in the absence of
defined requirements for the machine owner, JCB
recommend that the machine compliance be maintained to
ensure safety of the operator and exposed persons and to
ensure the correct environmental performance. Your
machine must not be altered in any way which could affect
or invalidate any of these requirements. For advice consult
your JCB dealer.
For its compliance as a new machine, your JCB and some
of its components may bear approval numbers and
marking's, and may have been supplied with a Declaration/
Certificate of Conformity. These marking's and documents
are relevant only for the country/region in which the
machine was first sold to the extent that the laws and
regulations required them.
Re-sales and import/export of machines across territories
with different laws and regulations can cause new
requirements to become relevant for which the machine
was not originally designed or specified. In some cases,
pre-owned machines irrespective of their age are
considered new for the purposes of compliance and may
be required to meet the latest requirements which could
present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's
on the machine and components, you should not assume
that compliance in a new market will be possible. In many
cases it is the person responsible for import of a pre-owned
machine into a market that becomes responsible for
compliance and who is also considered the manufacturer.
JCB may be unable to support any product compliance
related enquiry for a machine which has been moved out
of the legislative country/region where it was first sold, and
in particular where a machine specification change or
additional certification would have been required in order
for the machine to be in compliance
Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– 516-40 from 2415604 to 2416000.
Using this Manual
T1-044
This manual is arranged to give you a good understanding
of the machine and its safe operation. It also contains
maintenance information and specification data. Read this
manual from front to back before using the machine for the
first time. Particular attention must be given to all the safety
aspects of operating and maintaining the machine.
If there is anything you are not sure about, ask your JCB
distributor or employer. Do not guess, you or others could
be killed or seriously injured.
General warnings in this chapter are repeated throughout
the book, as well as specific warnings. Read all the safety
statements regularly, so you do not forget them.
Remember that the best operators are the safest
operators.
The illustrations in this manual are for guidance only.
Where the machines differ, the text and or the illustration
will specify.
This manual contains original instructions, verified by the
manufacturer (or their authorised representative).
JCB Compact Products,
Harewood Estate,
Leek Road,
Cheadle,
Stoke on Trent,
ST14 5JP.

Introduction
About This Manual
4 4
9821-9750-2
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.
All optional equipment included in this manual may not be
available in all territories.
Left Side, Right Side
In this manual, 'left' Aand 'right' Bmean your left and right
when you are seated correctly in the machine.
447200-2
Fig 1.
Cab/Canopy
T1-003_2
This manual frequently makes references to the cab. For
instance, 'do not operate the machine without a manual in
the cab'. It should be noted that these statements also
apply to canopy build machines.
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: KCross
References (T4).

Introduction
Machine Description
5 5
9821-9750-2
Machine Description
The JCB 516-40
Variable reach rough terrain truck, designed to carry an
extending boom with a carriage mounted on the front to
which forks or an approved attachment can be fitted.
When used normally, the machine lifts and places loads by
extending/retracting, raising/lowering the boom.
Intended Use
The machine is intended to be used under normal
conditions for the applications described in this manual. If
the machine is used for other purposes or in dangerous
environments, for example in a flammable atmosphere or
in areas with dust containing asbestos, special safety
regulations must be followed and the machine must be
equipped for use in these environments.
Component Location
Note: The illustration(s) show a typical machine model;
your machine may look different from the model shown.
T042520-C1
Fig 2.
1Boom
2Carriage
3ROPS/FOPS Cab
4Engine Cover
5Hydraulic Tank Filler
6Fuel Tank Filler
7Battery
8Proximity Retract Sensor (Option)
8

Introduction
Safety Check List
6 6
9821-9750-2
Safety Check List
P5-1010_3
Safety - Yours and Others
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.
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.
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
General Safety
T1-043
!MWARNING
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.
INT-1-4-1
!MWARNING
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
!MWARNING
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.
INT-1-3-6_2
!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

Introduction
Safety Check List
7 7
9821-9750-2
!MWARNING
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.
8-1-2-4
!MWARNING
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.
Switch off and do not use your mobile phone when
refuelling the machine.
INT-3-3-9
!MWARNING
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
!MWARNING
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
!MWARNING
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
!MDANGER
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
5-1-1-2
!MWARNING
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.
INT-1-3-10_2