background image

 01 - Machine

 03 - Safety

 18 - Operating Safety

01 - 8

9823/0650-1

01 - 8

18 - Operating Safety
Introduction

Training

Make sure that you have had adequate training and

that you are confident in your ability to operate the

machine safely before you use it. Practice using the

machine and its attachments until you are completely

familiar  with  the  controls  and  what  they  do.  With

a  careful,  well  trained  and  experienced  operator,

your machine is a safe and efficient machine. With

an  inexperienced  or  careless  operator,  it  can  be

dangerous. Do not put your life, or the lives of others,

at risk by using the machine irresponsibly. Before you

start to work, tell your colleagues what you will be

doing and where you will be working. On a busy site,

use a signalman.
Before doing any job not covered in this manual, find

out the correct procedure. Your local JCB distributor

will be glad to advise you.

Fuel

Fuel is flammable, keep naked flames away from the

fuel  system.  Stop  the  engine  immediately  if  a  fuel

leak is suspected. Do not smoke while refuelling or

working on the fuel system. Do not refuel with the

engine  running.  Completely  wipe  off  any  spilt  fuel

which could cause a fire. There could be a fire and

injury if you do not follow these precautions.

Machine Condition

A defective machine can injure you or others. Do not

operate a machine which is defective or has missing

parts. Make sure the maintenance procedures in this

manual are completed before using the machine.

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 or additional equipment.

Engine/Steering Failure

If the engine or steering fails, stop the machine as

quickly as possible. Do not operate the machine until

the fault has been corrected.

Exhaust Gases

Machine exhaust gases can harm and possibly kill

you or bystanders if they are inhaled. Do not operate

the machine in closed spaces without making sure

there  is  good  ventilation.  If  possible,  install  an

exhaust extractor. If you begin to feel drowsy, stop

the machine at once and get into fresh air.

Worksites

Worksites  can  be  hazardous.  Examine  the  site

before working on it. You could be killed or injured

if  the  ground  gives  way  under  your  machine  or  if

piled material collapses onto it. Check for potholes

and hidden debris, logs, ironwork etc. Any of these

could  cause  you  to  lose  control  of  your  machine.

Check for utilities such as electric cables (overhead

and  underground),  gas  and  water  pipes  etc.  Mark

the positions of the underground cables and pipes.

Make sure that you have enough clearance beneath

overhead cables and structures.

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. Worksites can be noisy, do

not rely on spoken commands.

Parking

An incorrectly parked machine can move without an

operator.  Follow  the  instructions  in  the  Operator's

Manual to park the machine correctly.

Banks and Trenches

Banked material and trenches can collapse. Do not

work or drive too close to banks and trenches where

there is danger of collapse.

Safety Barriers

Unguarded  machines  in  public  places  can  be

dangerous. In public places, or where your visibility

is reduced, place barriers around the work area to

keep people away.

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.

Hazardous Atmospheres

This  machine  is  designed  for  use  in  normal  out

door  atmospheric  conditions.  It  must  not  be  used

in  an  enclosed  area  without  adequate  ventilation.

Do  not  use  the  machine  in  a  potentially  explosive

atmosphere, i.e. combustible vapours, gas or dust,

without first consulting your JCB dealer.

Regulations

Obey all laws, worksite and local regulations which

affect you and your machine.

Summary of Contents for 432ZX PLUS

Page 1: ...l You must understand and follow the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operato...

Page 2: ...9823 0650 1 Notes Find manuals at https best manuals com...

Page 3: ...VICE MANUAL Volume 1 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 2 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 3 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 4 432ZX PLUS EN 9823 0650 Find manual...

Page 4: ...Notes 9823 0650 1 Find manuals at https best manuals com...

Page 5: ...ting Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Ma...

Page 6: ...9823 0650 1 2018 04 05 Acronyms Glossary PIL Parts Identification List Find manuals at https best manuals com...

Page 7: ...y Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessme...

Page 8: ...Notes 01 2 9823 0650 1 01 2 Find manuals at https best manuals com...

Page 9: ...ial hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the...

Page 10: ...dous situation which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The si...

Page 11: ...e of medicines which can cause drowsiness 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 Mobile Ph...

Page 12: ...lic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure th...

Page 13: ...composition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater tha...

Page 14: ...y kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel dro...

Page 15: ...ee clearly Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...2 A A Lift arm lowered 1 If necessary empty the shovel 2 Make sure that the machine is parked correctly in the straight ahead position on solid level ground 3 Lower the lift arm and put the attachmen...

Page 19: ...age position 9 Put a maintenance strut in position around the ram on one side of the machine and lock the strut in position with the strap 10 Put the other maintenance strut in position around the ram...

Page 20: ...on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery by means of the battery isolator if installed when you are not using electrical power If you...

Page 21: ...chine 06 About this Manual 01 15 9823 0650 1 01 15 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18 01 06 09 Left Hand Side Right Hand Side...

Page 22: ...Notes 01 16 9823 0650 1 01 16...

Page 23: ...ual 03 Model and Serial Number 01 17 9823 0650 1 01 17 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 2609501...

Page 24: ...information is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults ch...

Page 25: ...09 Left Hand Side Right Hand Side 01 19 9823 0650 1 01 19 09 Left Hand Side Right Hand Side Introduction In this manual left and right mean your left and right when you are seated correctly in the mac...

Page 26: ...01 Machine 09 Description 01 20 9823 0650 1 01 20 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22...

Page 27: ...21 9823 0650 1 01 21 12 Main Component Locations Introduction Figure 6 A Front work lights B Rear work lights C Exhaust stack D Rain cap air filter system Pre air cleaner E Engine cover F Rear grille...

Page 28: ...Locations 01 22 9823 0650 1 01 22 15 Service Point Locations Introduction Figure 7 D E F B A G C A Coolant filler cap B Coolant expansion tank C Fuel filler cap D Engine oil filter E Transmission dips...

Page 29: ...iption 15 Service Point Locations 01 23 9823 0650 1 01 23 Figure 8 A A Engine oil drain plug Figure 9 A B A Battery B Battery Isolator Figure 10 A Hydraulic tank filler B Fuel filter C Water separator...

Page 30: ...23 0650 1 01 24 Figure 11 B A C D A Access panel B Fuel tank C Drain plug D Strainer Figure 12 A B D C A Access panel B Hydraulic tank C Drain plug D Strainer Figure 13 A A Radiator Figure 14 A A Hydr...

Page 31: ...01 Machine 33 Cleaning 01 25 9823 0650 1 01 25 33 Cleaning Contents Page No 01 33 00 General 01 27...

Page 32: ...Notes 01 26 9823 0650 1 01 26...

Page 33: ...ender the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures...

Page 34: ...aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oi...

Page 35: ...3 03 Attachments Couplings and Load Handling Contents Page No 03 00 Attachments 03 00 00 General 03 3 03 09 Lift Arm Quickhitch 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 03 30 Shovel 03...

Page 36: ...Notes 9823 0650 1 2018 04 03...

Page 37: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9823 0650 1 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 38: ...Notes 03 2 9823 0650 1 03 2...

Page 39: ...ients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactu...

Page 40: ...r s Manual do not install it use it or remove it until you have obtained read and understood the pertinent information Install attachments only on the machines for which they were designed WARNING Loa...

Page 41: ...03 Attachments Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9823 0650 1 03 5 09 Lift Arm Quickhitch Contents Page No 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8...

Page 42: ...Notes 03 6 9823 0650 1 03 6...

Page 43: ...buckets shovels and other attachments on the machine Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations but when installed o...

Page 44: ...d For more information on the servo control lever and the auxiliary controls A Quickhitch isolator valve is installed on all machines This valve can be used to hydraulically operate the locking pins t...

Page 45: ...03 Attachments Couplings and Load Handling 30 Shovel 03 9 9823 0650 1 03 9 30 Shovel Contents Page No 03 30 00 General 03 11...

Page 46: ...Notes 03 10 9823 0650 1 03 10...

Page 47: ...ctly mounted on to a lift arm assembly or mounted to the lift arm via a quickhitch assembly There are a vast amount and size of shovels used for numerous applications A shovel can be used to scoop up...

Page 48: ...hments Couplings and Load Handling 30 Shovel 00 General 03 12 9823 0650 1 03 12 Health and Safety CAUTION This component is heavy It must only be removed or handled using a suitable lifting method and...

Page 49: ...gulations Remove 1 Make the machine safe with the lift arm lowered Refer to PIL 01 03 27 2 Remove the bolt x2 washer x2 from the pivot pin that attaches the shovel and the shovel lever 3 Remove the bo...

Page 50: ...plings and Load Handling 30 Shovel 00 General 03 14 9823 0650 1 03 14 Figure 17 A B F H D B E G G J C F H K E G G J C A Shovel B Z bar linkage C Loader arm D Bolt 1 E Washer F Pivot pin G Seal H Beari...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

Reviews: