Robot 190 & 1110 Op - Manuals

www.WorkshopManuals.co.
uk
Operator Handbook
ROBOT 190, 190HF, 1110, 1110HF

From serial number 888000 onwards
! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES !
Publication Number 9801/4320 January 2002 Issue 4
Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

SAFETY NOTICES
! WARNING
Study This Handbook Before Starting The Machine
You must understand and follow the instructions in this handbook. You must
observe all relevant laws and regulations. If you are unsure about anything, ask your
JCB distributor or employer. Do not guess, you or others could be killed or
seriously injured.
INT-1-1-1
! CAUTION
Do not fit an attachment to this machine which is not JCB approved. Consult your
JCB distributor before fitting any non approved attachment.
8-4-1-6
In this handbook and on the machine there are safety notices. Each notice starts
with a signal word. The meanings of the signal words 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
MACHINE SECURITY
Vandalism and theft of unattended machines is an ever increasing problem and

JCB is doing everything possible to help combat this.
JCB PLANTGUARD is a comprehensive package available to help you safeguard

your machine. It includes such devices as vandal proof covers, window etching,
immobiliser, concealed serial number, battery isolator, Tracker security system
and much more.
Remember that the fitting of any one of these security devices will help to
minimise not only the damage or loss of your machine but also subsequent lost
productivity. It could also result in reduced insurance premiums.
Your JCB Distributor or Dealer will be pleased to provide information on any of

these sensible precautions. ACT NOW!
INT-1-2-4
4320-1

i
CONTENTS i
INTRODUCTION Page Page
About this Handbook Cab Heater Unit (optional) ..................................... 33

Machine Models ........................................................ 1
Using this Handbook ................................................. 1 Cab Interior Light (optional) .................................. 34
Location of Handbook ............................................... 1
Units of Measurement ............................................... 1 Loader Controls (servo machines)
Page Numbering ....................................................... 1 Loader Arm/Shovel Control Lever
Left Side, Right Side ................................................. 1 (single lever drive control) ........................................ 34
Using the Machine .................................................... 1 Loader ArmControl Lever (dual lever drive control) .... 34A
Shovel Control Lever (dual lever drive control) ........... 34A
The JCB Skid Steer Loader Auxiliary Attachments Control Pedal (optional) ........... 35
Machine Description .................................................. 2 Float Control Switch (optional) ................................... 35
Safety First - Yours and Other People's ................ 3 Loader Controls (manual machines)
Loader Arm Control - Lever Option ............................ 36
Safety Check List Shovel Control - Lever Option .................................... 36
General Safety .......................................................... 3 Loader Arm/Shovel Control - Pedal Option ................ 37
Operating Safety ....................................................... 4 Auxiliary Attachments Control (optional) .................... 37
Maintenance Safety .................................................. 5
Before Starting the Engine .................................... 38
Safety Decals .......................................................... 8
Starting the Engine ................................................ 39
Identifying Your Machine
Machine Identification Plate ..................................... 9 Jump-Starting the Engine ..................................... 40
Typical Vehicle Identification Number (VIN) ................ 9
Unit Identification ...................................................... 9 Rotating Beacon (optional) ................................... 41
JCB Immobiliser Option ........................................ 10 Travelling Position

Travelling on Site ..................................................... 41
Travelling on Public Roads ...................................... 41
OPERATION Travelling on Public Roads (UK only) ......................... 42
Introduction ............................................................ 21 Driving the Machine

Drive Control Lever (servo single lever control) ........... 43
Before Entering the Cab ........................................ 21 Drive Control Levers
(servo dual lever drive & manual controls) ................ 44
Entering/Leaving the Cab ........................................ 22 Getting Moving ......................................................... 45
Stopping and Parking ............................................... 45
Cab Door and Vents Operating Practices .................................................. 46
Opening and Closing the Cab Door ......................... 23
Ventilation of Optional Glazed Cab .......................... 23 Using the Attachments and Site Safety ............... 47
Emergency Exits .................................................... 24 Quickhitch Control

Engaging the Shovel/Attachments ........................... 49
Seat and Safety Restraint Disengaging the Shovel/Attachments ...................... 50
Seat Adjustment .......................................................... 25
Seat Removal and Replacement ................................ 25 Working with the Loader
Safety Restraint .......................................................... 25 Filling the Shovel ...................................................... 51
Loading a Truck ....................................................... 51
Controls, Switches and Instruments Scraping and Cutting ............................................... 51
Cab Layout (servo machines) ................................ 26
Cab Layout (manual machines) ............................. 28 Operating in Low Temperatures ........................... 52
Switches ..................................................................... 30
Warning Indicators ................................................... 31 Operating in High Temperatures .......................... 52
Seat Belt Moving a Disabled Machine

Fastening the Seat Belt ............................................ 32 Preparation for Towing/Winching ............................... 53
Releasing the Seat Belt ............................................ 32 After Towing/Winching ................................................ 53
Checking Seat Belt Operation .................................. 32
4320-2

ii
CONTENTS ii
OPERATION (cont’d) Page Page
Transporting the Machine Greasing (50 Hours)

Using a Trailer ......................................................... 54 Loader Arm Pivot Point ............................................ 69
Using a Truck .......................................................... 55 Lift Ram Pivots ......................................................... 69
Transportation Safety .............................................. 55
Greasing and Oiling (100 Hours)
Lifting the Machine Safety Restraint mechanism ...................................... 70
Safe Lifting Procedure .............................................. 57 Control Linkage (manual machines) ........................... 70
Throttle Pedal (if fitted) ............................................. 70
Emergency Load Lower Procedure ....................... 56
Engine Air Filter
Testing the Parking Brake ........................................ 57 Changing the Elements ........................................... 71
Engine Oil and Filter

MAINTENANCE Checking the Oil Level ............................................. 72
Changing the Oil and Filter ...................................... 72
Service Requirements ........................................... 61
Engine Cooling System
Lubricants - Health and Safety Coolant Mixtures ...................................................... 74
Hygiene ................................................................... 62 Checking the Coolant Level ..................................... 74
Storage .................................................................... 62 Changing the Coolant .............................................. 75
Waste Disposal ........................................................ 62 Cleaning the Coolant Radiator and Oil Cooler ......... 75
Handling ................................................................... 62
First Aid - Oil ............................................................ 62 Engine Alternator Belt
Spillage .................................................................... 62 Checking the Alternator Belt Tension ........................ 76
Fires ......................................................................... 62 Adjusting the Alternator Belt ..................................... 76
Service Schedules Drive Chain Lubrication

Every 10 Operating Hours or Daily .......................... 63 Checking the Oil Level ............................................. 77
Every 50 Operating Hours or Weekly ...................... 63 Changing the Oil ...................................................... 77
Every 100 Operating Hours or 2 Weekly ................. 63
Every 250 Operating Hours or Monthly ................... 64 Fuel System
Every 500 Operating Hours or 6 Monthly ................ 64 Types of Fuel ........................................................... 78
Every 1000 Operating Hours or Yearly .................... 64 Fuel Standards ........................................................ 78
Every 2000 Operating Hours or 2 Yearly ................. 64 Low Temperature Fuels ........................................... 78
Petrol ....................................................................... 78
Cleaning the Cab Floor and Rear Chassis ............. 65 Advice ...................................................................... 78
Fatty Acid Methyl Ester Fuels .................................... 78
ROPS/FOPS Cab/Canopy Filling the Tank ........................................................ 78
Checking the ROPS/FOPS Cab/Canopy ................. 65 Draining the Fuel Sediment Bowl .............................. 79
Changing the Fuel Filter Element .............................. 80
Loader Arm Safety Strut Bleeding the Fuel System .......................................... 80
Installing the Safety Strut ......................................... 66
Removing the Safety Strut ....................................... 66 Hydraulic System
Checking the Oil Level ............................................ 81
Engine Compartment Access Changing the Filter .................................................. 81
Top Cover ................................................................. 67 Changing the High-flow Filter .................................... 82
Rear Panel ................................................................. 67
Radiator and Oil Cooler ............................................... 67 Battery
Safety ...................................................................... 83
Cleaning the Radiator and Oil Cooler ....................... 67 Checking the Electrolyte Level ................................ 84
Warning Symbols ..................................................... 84
Seat Belt
Checking Seat Belt Condition and Security .............. 68 Electrical System
Fuses .......................................................................... 85
Greasing (10 Hours) Primary Fuses ............................................................ 86
Quickhitch Pivot Points ............................................. 68 Relays ........................................................................ 86
Light Bulbs ................................................................. 86
4320-4

iii
CONTENTS iii
MAINTENANCE (cont’d) Page
Windscreen Washer ............................................... 87
Tracks
Track Adjustment ....................................................... 87
Tyres and Wheels

Inflating the Tyres ..................................................... 88
Renewing Segments of Optional Non-Inflatable Tyres 88
Checking the Wheel Nut Torques ............................ 88
Fluids, Capacities and Lubricants ........................ 89
Obtaining Replacement Parts ................................ 89
Storage
Storing the Machine ................................................... 90
OPTIONAL ATTACHMENTS Page
Introduction ........................................................... 101
Quick Release Couplings ..................................... 102
Connecting/Disconnecting Hydraulic Hoses ..... 103
Attachments Controls ............................................ 104
Shovels .................................................................... 105
6-in-1 Shovel ............................................................ 105
Pallet Forks .............................................................. 108
Manure/Silage Fork with Top Grab ........................ 109
Attachment Frame ................................................... 110
Wheel Mounted Tracks ........................................... 111
SPECIFICATION
General Specification ............................................. 131
Tyre Specification ................................................... 131
Static Dimensions - Wheeled Machines ................ 132
Static Dimensions - Tracked Machines ................ 134
Noise and Vibration Data

Machines up to serial no. 888055 ............................. 136
Machines from serial no. 888056 .............................. 137
4320-3

1
INTRODUCTION 1
ABOUT THIS HANDBOOK
Machine Models Page Numbering

This handbook provides information for the following The page numbering system in this handbook is not
models in the JCB Skid Steer Loader range: continuous. There is a gap between sections. This allows
for the insertion of new pages in later issues of the
Robot 190, 190HF, 1110 and 1110HF handbook.
from serial no. 888000
Left Side, Right Side
The handbook covers both servo and manual controls
although some illustrations may show only one type. In this handbook, 'left' B and 'right' C mean your left and
Information also covers both wheeled and tracked right when you are seated correctly in the machine.
machines unless otherwise stated.
Using the Machine
Using this Handbook
To use the Skid Steer Loader efficiently and safely you
The illustrations in this handbook are for guidance only. must know the machine and have the skill to use it. This
Where the machines differ, the text and/or the illustration handbook instructs you on the machine, its controls and its
will specify. safe operation. It is not a training manual on the art of
loading. If you are a new operator, get yourself trained in
This handbook is arranged to give you a good the skills of using a Skid Steer Loader before trying to work
understanding of the machine and its safe operation. It also with it. If you do not, you will not do your job well, and you
contains maintenance information and specification data. will be a danger to yourself and others.
Read this handbook 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.
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.
Finally, treat this handbook as part of the machine. Keep it

clean and in good condition. Do not operate the machine
without a handbook in the cab. 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.
A
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.
INT-1-2-5/1
332720
Location of Handbook
The handbook is located in the case provided which is
behind the seat, as shown at A. The handbook should C
always be returned to its correct stowage.
Units of Measurement
In this handbook, the S.I. system of units is used. For
example, liquid capacities are given in litres. The Imperial
units follow in parenthesis () eg 28 litres (6 UK gal).
B 378210
4320-1

2
INTRODUCTION 2
THE JCB SKIDSTEER LOADER
Machine Description
ROPS/FOPS
CAB
The Robot is a self propelled skid steer FRONT
machine fitted with either wheels or WORKING
tracks. The main structural support is LIGHTS
designed to carry a front mounted
carriage onto which a shovel or an
approved attachment can be fitted.
When used normally with a shovel FUEL QUICKHITCH

fitted, the machine loads or excavates TANK
through forward motion of the machine
and lifts, transports and discharges
material.
LOADER
ARM
378220
RUBBER
TRACKS
378240
REAR WORKING LIGHT
BATTERY
ENGINE
TOP COVER
ENGINE
COMPARTMENT
REAR COVER
HYDRAULIC HYDRAULIC SIGHT GLASS

TANK 378230
4320-1

3
INTRODUCTION 3
SAFETY FIRST - YOURS AND OTHER PEOPLE'S
All construction and agricultural equipment can be Do not work with the machine until you are sure that you
hazardous. When a Skid Steer Loader is correctly operated can control it.
and properly maintained, it is a safe machine to work with. Do not start any job until you are sure that you and those
But when it is carelessly operated or poorly maintained it around you will be safe.
can become a danger to you (the operator) and others.
If you are unsure of anything, about the machine or the job,
In this handbook and on the machine you will find warning ask someone who knows. Do not assume anything.
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not fully Remember
understand the warning messages, ask your employer or BE CAREFUL
JCB distributor to explain them. BE ALERT
BE SAFE
But safety is not just a matter of responding to the INT-1-3-1/1
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.
SAFETY CHECK LIST
General Safety
! WARNING ! WARNING
Handbook Raised Attachments
You and others can be injured if you operate or maintain Raised attachments can fall and injure you. Do not walk or
the machine without first studying this handbook. Read the work under raised attachments unless they are safely
safety instructions before operating the machine. If you do blocked.
not understand anything, ask your employer or JCB INT-1-3-8
distributor to explain it. Keep this handbook clean and in
good condition. Do not operate the machine without a ! WARNING
handbook in the cab, or if there is anything on the machine Clothing
you do not understand.
You can be injured if you do not wear the proper clothing.
INT-1-3-2
Loose clothing can get caught in the machinery. Wear
! CAUTION protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
Regulations
fitting overall, ear-protectors and industrial gloves. Keep
Obey all laws, work site and local regulations which affect
cuffs fastened. Do not wear a necktie or scarf. Keep long
you and your machine.
hair restrained.
INT-1-3-3
INT-1-3-6
! WARNING ! WARNING
Decals
You can be injured if you do not obey the decal safety Lifting Equipment
instructions. Keep decals clean. Replace unreadable or You can be injured if you use faulty lifting equipment. Make
missing decals with new ones before operating the sure that lifting equipment is in good condition. Make sure
machine. Make sure replacement parts include warning that lifting tackle complies with all local regulations and is
decals where necessary. suitable for the job. Make sure that lifting equipment is
INT-1-3-4 strong enough for the job.
INT-1-3-7
! 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
4230-1

4
INTRODUCTION 4
SAFETY CHECK LIST

(continued)
General Safety (continued)
! WARNING ! CAUTION
Alcohol and Drugs Machine Modifications
It is extremely dangerous to operate machinery when This machine is manufactured in compliance with
under the influence of alcohol or drugs. Do not consume legislative and other requirements. It should not be altered
alcoholic drinks or take drugs before or whilst operating in any way which could affect or invalidate any of these
the machine or attachments. Be aware of medicines which requirements. For advice consult your JCB Distributor.
can cause drowsiness.
INT-1-3-9 Reference should also be made to Optional Attachments
section where appropriate.
INT-1-3-10
Operating Safety
! WARNING
! WARNING Rollover
Practice Should the machine start to roll over, you can be crushed
You or others can be killed or seriously injured if you do if you try to leave the cab. If the machine starts to roll over,
unfamiliar operations without first practising them. DO NOT TRY TO JUMP FROM THE CAB. STAY IN THE
Practise away from the work site on a clear area. Keep CAB, WITH YOUR SEAT BELT FASTENED.
other people away. Do not perform new operations until INT-2-1-12
you are sure you can do them safely.
INT-2-1-1 ! WARNING
ROPS/FOPS Structure
! WARNING The machine is fitted with a Roll Over Protection Structure
Machine Condition (ROPS) and a Falling Objects Protection Structure (FOPS).
A defective machine can injure you or others. Do not You could be killed or seriously injured if you operate the
operate a machine which is defective or has missing parts. machine with a damaged or missing ROPS/FOPS. If the
Make sure the maintenance procedures in this handbook ROPS/FOPS has been in an accident, do not use the
are completed before using the machine. machine until the structure has been renewed.
INT-2-1-2
Modifications and repairs that are not approved by the
! WARNING manufacturer may be dangerous and will invalidate the
ROPS/FOPS certification.
Controls INT-2-1-9/3
You or others can be killed or seriously injured if you
operate the control levers from outside the cab. Operate ! WARNING
the controls levers only when you are correctly seated Seat Belts
inside the cab. The ROPS/FOPS cab is designed to give you protection in
INT-2-1-3
an accident. If you do not wear your seat belt, you could
! WARNING be thrown around inside the cab or thrown out of the
machine and crushed. You must wear a seat belt when
Machine Limits
using the machine. Fasten the seat belt before starting the
Operating the machine beyond its design limits can
engine.
damage the machine, it can also be dangerous. Do not 2-2-1-9
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved ! CAUTION
modifications. Cold Starting
INT-2-1-4
Do not use ether or other starting fluids to assist cold
! WARNING starting. Using these fluids may result in an explosion
Passengers causing possible injury and/or damage to the engine.
3-2-1-9
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
4230-1

5
INTRODUCTION 5
SAFETY CHECK LIST

(continued)
Operating Safety (continued)

! CAUTION ! WARNING
Do not attempt to operate the machine immediately after
starting in cold conditions i.e. below -5°C (20°F). The Ramps and Trailers
machine may not respond properly to control movements. Water, mud, ice, grease and oil on ramps or trailers can
Allow at least 10 minutes warm up time with the engine at cause serious accidents. Make sure ramps and trailers are
half throttle. Operate the arm and shovel services to warm clean before driving onto them. Use extreme caution when
the hydraulic oil. driving onto ramps and trailers. Always reverse up a ramp
3-1-1-5/1 if unloaded, travel forwards if loaded. Always reverse
down a ramp if loaded, travel forwards if unloaded.
! WARNING 3-1-1-3/1
Exhaust Gases ! DANGER

Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed Sparks
spaces without making sure there is good ventilation. If Explosions and fire can be caused by sparks from the
possible, fit an exhaust extension. If you begin to feel exhaust or the electrical system. Do not use the machine
drowsy, stop the machine at once. Get out of the cab into in closed areas where there is flammable material, vapour
fresh air. or dust.
INT-2-2-10
INT-2-1-10
! WARNING ! WARNING
Hazardous Atmospheres Safe Working Loads
This machine is designed for use in normal out door Overloading the machine can damage it and make it
atmospheric conditions. It should not be used in an unstable. Study the lifting and/or digging specifications in
enclosed area without adequate ventilation. Do not use this handbook before using the attachments.
INT-2-2-11/1
the machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting
your JCB Distributor.
INT-2-1-14
! WARNING
Visibility
Accidents can be caused by working in poor visibility.
Keep windows clean and use your lights to improve
visibility. Do not operate the machine if you cannot see
properly.
INT-2-1-11
Maintenance Safety
! WARNING ! WARNING
Communications Repairs
Bad communications can cause accidents. If two or more Do not try to do repairs or any other type of maintenance
people are working on the machine, make sure each is work you do not understand. Get a Service Manual from
aware of what the others are doing. Before starting the your JCB distributor, or get the work done by a specialist
engine make sure the others are clear of the danger areas; engineer.
examples of danger areas are: the rotating blades and belt INT-3-1-1
on the engine, the attachments and linkages, and
anywhere beneath or behind the machine. People can be ! WARNING
killed or injured if these precautions are not taken. Soft Ground
INT-3-1-5 A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
4320-1

6
INTRODUCTION 6
SAFETY CHECK LIST

(continued)
Maintenance Safety (continued)
! WARNING ! WARNING
Airborne particles of light combustable material such as Hydraulic Oil
straw, grass, wood shavings, etc. must not be allowed to Fine jets of Hydraulic oil at high pressure can penetrate
accumulate within the engine compartment or in the the skin. Do not use your fingers to check for Hydraulic oil
propshaft guards (when fitted). Please inspect these areas leaks. Do not put your face close to suspected leaks. Hold
frequently and clean at the beginning of each work shift or a piece of cardboard close to suspected leaks and then
more often if required. Before opening the engine cover inspect the cardboard for signs of Hydraulic oil. If
ensure that the top is clear of debris. Hydraulic oil penetrates your skin, get medical help
5-3-1-12/2 immediately.
INT-3-1-10/1
! WARNING
Raised Machine ! WARNING
NEVER position yourself or any part of your body under a Hydraulic Pressure
raised machine which is not properly supported. If the Hydraulic fluid at pressure can injure you. Make the
machine moves unexpectedly you could become trapped machine safe before connecting or disconnecting quick
and suffer serious injury or be killed. release couplings; stop the engine and operate the
INT-3-3-7/1 auxiliary attachment control a few times to vent residual
hydraulic pressure in the attachment hoses.
! WARNING 3-4-1-7
Modifications and Welding
Non-approved modifications can cause injury and ! CAUTION
damage. Parts of the machine are made from cast iron; Rams
welds on cast iron can weaken the structure and break. The efficiency of the rams will be affected if they are not
Do not weld cast iron. Contact your JCB distributor for kept free of solidified dirt. Clean dirt from around the rams
advice before modifying the machine. regularly. When leaving or parking the machine, close all
INT-3-1-2/1 rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
! WARNING
Metal Splinters ! WARNING
You can be injured by flying metal splinters when driving Hydraulic Hoses
metal pins in or out. Use a soft faced hammer or drift to Damaged hoses can cause fatal accidents. Inspect the
remove and fit metal pins. Always wear safety glasses. hoses regularly for:
INT-3-1-3
Damaged end fittings
! WARNING Chafed outer covers
Ballooned outer covers
Diesel Fuel Kinked or crushed hoses
Diesel fuel is flammable; keep naked flames away from the Embedded armouring in outer covers
machine. Do not smoke while refuelling the machine or Displaced end fittings.
working on the engine. Do not refuel with the engine INT-3-3-2
running. There could be a fire or injury if you do not follow
these precautions. ! WARNING
INT-3-2-2
Oil
! WARNING Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
Petrol contaminants which can cause skin cancer. Do not handle
Do not use petrol in this machine. Do not mix petrol with used engine oil more than necessary. Always use barrier
diesel fuel; in storage tanks the petrol will rise to the top cream or wear gloves to prevent skin contact. Wash skin
and form flammable vapours. contaminated with oil thoroughly in warm soapy water. Do
INT-3-1-6
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
4320-1

7
INTRODUCTION 7
SAFETY CHECK LIST

(continued)
Maintenance Safety (continued)
! WARNING ! CAUTION
Electrical Circuits 'O' rings, Seals and Gaskets
Understand the electrical circuit before connecting or Badly fitted, damaged or rotted 'O' rings, seals and
disconnecting an electrical component. A wrong gaskets can cause leakages and possible accidents.
connection can cause injury and/or damage. Renew whenever disturbed unless otherwise instructed.
INT-3-1-4 Do not use Trichloroethane or paint thinners near 'O' rings
and seals.
Do not disconnect the battery while the engine is running INT-3-2-12
otherwise the electrical circuits may be damaged.
INT-3-1-14
! CAUTION
! WARNING Cleaning
Fluoroelastomeric Materials Cleaning metal parts with incorrect solvents can cause
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB corrosion. Use only recommended cleaning agents and
machines contain fluoroelastomeric materials such as solvents.
INT-3-2-11
Viton, Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly
corrosive hydrofluoric acid. THIS ACID CAN SEVERELY
! WARNING
BURN. Fires
If your machine is equipped with a fire extinguisher, make
New fluoroelastomeric components at ambient sure it is checked regularly. Keep it in the operator's cab
temperature require no special safety precautions. until you need to use it.
Used fluoroelastomeric components whose temperatures Do not use water to put out a machine fire, you could
have not exceeded 300°C require no special safety spread an oil fire or get a shock from an electrical fire. Use
precautions. If evidence of decomposition (e.g. charring) is carbon dioxide, dry chemical or foam extinguishers.
found, refer to the next paragraph for safety instructions Contact your nearest fire department as quickly as
DO NOT TOUCH COMPONENT OR SURROUNDING possible. Firefighters should use self-contained breathing
AREA. apparatus.
INT-3-2-7/1
Used fluoroelastomeric components subjected to

temperatures greater than 300°C (e.g. engine fire) must be
treated using the following safety procedure. Make sure
that heavy duty gloves and special safety glasses are
worn:
1 Ensure that components have cooled then remove

and place material into plastic bags.
2 Thoroughly wash contaminated area with 10%

calcium hydroxide or other suitable alkali solution, if
necessary use wire wool to remove burnt remains.
3 Thoroughly wash contaminated area with detergent

and water.
4 Contain all removed material, gloves etc. used in this

operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected

area with a continuous supply of clean water or with
calcium hydroxide solution for 15-60 minutes. Get medical
attention immediately.
INT-3-3-5/1
4320-1

8
INTRODUCTION 8
SAFETY DECALS
! WARNING ! WARNING
Decals on the machine warn you of particular hazards. If you need eye-glasses for reading, make sure you wear
Each decal is attached close to a part of the machine them when reading the safety decals. Decals are
where there is a possible hazard. Read and make sure you strategically placed around the machine to remind you of
understand the safety message before you work with or possible hazards. Do not over-stretch or place yourself in
on that part of the machine. dangerous positions to read the decals.
INT-3-3-4
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment points Note: All labels illustrated are in English. Your JCB
are shown on the following pages. Each decal has a part Distributor will advise you on the availability of labels in
number printed on it, use this number to order a new other languages.
decal from your JCB distributor.
INT-3-3-3
ATTENTION !
A THE ENGINE WILL NOT START IF
HIGH FLOW (IF FITTED) IS SWITCHED
ON
B THE AUXILIARY HYDRAULICS CAN STILL
BE OPERATED WHEN THE DRIVE
CONTROL AND LOADER CONTROL ARE
DANGER
ISOLATED UNLESS THE LATCH IS
MANUALLY ENGAGED YOU OR OTHERS CAN BE KILLED
817/16642
OR SERIOUSLY INJURED IF YOU
817/16642-2 817/03149 OPERATE THE CONTROL LEVERS
FROM OUTSIDE THE CAB.
OPERATE THE CONTROL LEVERS
ONLY WHEN YOU ARE CORRECTLY
SEATED INSIDE THE CAB
817/04330
817/04330
817/03150
P P
817/17403
817/17403
817/01639
4320-1

9
INTRODUCTION 9
IDENTIFYING YOUR MACHINE
Machine Identification Plate

The machine identification plate is located as shown at A.
The plate is stamped with the machine serial number and A
the serial numbers of the major individual units.
Typical Vehicle Identification Number (VIN)

SLP 190 S B V E 888001
1 2 3 4 5 6 7
1 World Manufacturer Identification 378260
2 Machine Model
3 Machine Type (S = Standard, H = High-flow)
J.C.BAMFORD EXCAVATORS LTD. BSI
4 Build Type (A = Canopy, B = Cab)
RM
R EG
ROCESTER, STAFFS, ENGLAND.
FI
R
ST
I
ERED
CONSTRUCTOR MADE IN UK
5 Year of Manufacture:
W = 1998 2 = 2002
X = 1999 3 = 2003 Vehicle Identification No. Product Identification No.
Y = 2000 4 = 2004
ENGINE SERIAL No. WEIGHT
1 = 2001 5 = 2005
PUMP SERIAL No. YEAR OF MANUFACTURE
6 Manufacturer Location (E = England) MODEL 80/1269/EEC MODEL 80/1269/EEC
POWER KW R.P.M. POWER KW R.P.M.
7 Product Identification Number (PIN) 160 32.5 2600 190 56.8 2200
170 34.4 2800 190 HF 56.8 2200
170 HF 34.4 2800 1110 65.3 2200
160 HF 32.5 2600 1110 HF 65.3 2200
1CX 34.4 2800 1CX HF 34.4 2800
Unit Identification 817/17187
The chassis serial number is stamped on the front face of

the chassis as shown at B.
The engine serial number is stamped on a label C on the

side of the cylinder block.
If any of the major 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 B
number or stamp out the old number.
378270
S181760
4320-1

10
INTRODUCTION 10
JCB IMMOBILISER OPTION
The JCB Immobiliser incorporates latest Electronic Follow the instructions below to Activate and Deactivate
Immobiliser technology and is operated by an the JCB Immobiliser system.
Electronically coded key.
Activation
The components required to operate the JCB Immobiliser
are: The vehicle is automatically immobilised 15 seconds after
switching off the engine ignition system.
Yellow JCB Immobiliser Electronically coded key.
Instrument panel mounted Immobiliser key receptacle. The L.E.D. (Light Emitting Diode) in the JCB Immobiliser
key receptacle flashes when the immobiliser is activated.
Deactivation
To start the vehicle engine the JCB Immobiliser Electronic

key must be inserted and removed from the Immobiliser
key receptacle, the L.E.D. will then extinguish indicating
the Immobiliser has deactivated. The vehicle ignition key is
operated to start the engine in the normal way but within
10 to 15 seconds otherwise the system will reactivate
itself.
If the Immobiliser key remains inserted in the receptacle

the engine will not start.
If the Immobiliser key is inserted in the receptacle for

longer than 15 seconds the L.E.D. in the Immobiliser key
receptacle will begin to flash indicating activation of the
system. To deactivate the Immobiliser first remove the
electronic key from the receptacle, then re-insert the key
and remove it within 5 to 10 seconds.
NEVER TURN OR ATTEMPT TO TURN THE JCB

IMMOBILISER ELECTRONIC CODED KEY WHEN IT
HAS BEEN INSERTED INSIDE THE KEY RECEPTACLE.
Additional and/or replacement Immobiliser Electronic keys

(Maximum of 5 keys) can be supplied on request from
242160 your approved installing JCB distributor provided that one
of the two Electronic keys originally supplied with the
Immobiliser is still available.
4230-1

21
OPERATION 21
INTRODUCTION
The aim of this part of the handbook is to guide the When you have familiarised yourself with the operating
operator step-by-step through the task of learning how to controls, gauges and switches, practise using them. Drive
operate the machine efficiently and safely. Read the the machine in an open space, clear of people. Get to
OPERATION section through from beginning to end. know the 'feel' of the machine and its driving controls.
Before starting the machine, sit in the operator's seat and Finally, do not rush the job of learning, make sure you fully
familiarise yourself with the layout of the cab. Use your understand everything in the OPERATION section. Take
handbook to identify each control lever, switch, gauge, your time and work efficiently and safely.
button and pedal. Do not guess. If there is anything you
do not understand, ask your JCB distributor. Remember
The operator must always be aware of events happening BE CAREFUL

outside the cab as well as inside the cab. Safety must BE ALERT
always be the most important feature when operating the BE SAFE
Skid Steer Loader.
BEFORE ENTERING THE CAB
The following checks should be made each time you 2 Check for Damage
return to the machine after leaving it for any period of time.
We advise you also to stop the machine occasionally a Inspect the machine generally for damaged and
during long work sessions and do the checks again. missing parts.
All these checks concern the serviceability of the machine. b Make sure that the shovel is secure and in good
Some concern your safety. Get your service engineer to condition.
check and correct any defects.
c Make sure that all pivot pins are secured correctly
! WARNING in place.
Walking or working under raised attachments can be
d Inspect the windows for cracks and damage.
hazardous. You could be crushed by the attachments
Glass splinters can blind you.
or get caught in the linkages.
e Check for oil, fuel and coolant leakages.
Lower the attachments to the ground before doing
these checks. If you are new to this machine, get an
3 Check the Fuel and Hydraulic Filler Caps
experienced operator to lower them for you.
Make sure the caps are tightly closed. (We also
If there is nobody to help you, study this handbook
recommend that you lock the fuel filler cap.)
until you have learned how to lower the attachments.
3-2-1-6
4 Check the Engine Compartment Rear Panel and
Top Cover
1 Check for Cleanliness
a Make sure the engine compartment rear panel is
a Clean the windows and light lenses. in position and secure (see MAINTENANCE
section).
b Remove dirt and debris, especially from around
the linkages, rams, pivot points and radiator. b Make sure the engine top cover is closed and
locked (see MAINTENANCE section).
c Make sure the cab step and handholds are clean
and dry.
d Clean all safety decals. Replace any that are

missing or cannot be read.
e Clean inside cab, remove debris from around

control pedals.
4320-1

22
OPERATION 22
BEFORE ENTERING THE CAB

(continued)
! WARNING b Segmented
i Check every segment of all four tyres for
You could be killed or injured if a machine tyre bursts.
damage.
Do not use the machine with damaged, incorrectly
inflated or excessively worn tyres.
2-2-1-2 ii Replace damaged segments (see Replacing
Segments of Non-Inflatable Tyres in
5 Check the Tyres MAINTENANCE section) to ensure machine
stability and also to prevent damage spreading
a Pneumatic to other segments.
i Make sure the tyres are correctly inflated, see
Inflating the Tyres in MAINTENANCE section c Solid
for a safe procedure for inflating the tyres. i Check all four tyres for damage.
ii Check for adequate tread depth, cut rubber ii Replace damaged tyres to ensure machine
and penetration by sharp objects. Do not use a stability.
machine with damaged tyres.
iii Keep wear on front and rear tyres equal. Swop
tyres from front to back if necessary.
6 Check Condition of the Seat Belt
Make sure the seat belt is working correctly and is not

damaged (see Seat Belt).
ENTERING/LEAVING THE CAB
! WARNING
Do not use the machine controls as handholds when
entering (or leaving) the machine
2-2-1-4
! CAUTION
Always face the machine when entering (and leaving)
the cab. Make sure your hands and shoes are clean
and dry. Otherwise you could slip and fall.
2-2-1-3
324911
4320-2

23
OPERATION 23
CAB DOOR AND VENTS
Opening and Closing the Door

Note: Whenever the door catch is released, the door
swings open automatically under pressure from a gas strut.
Strut life can be extended if the door is prevented from
swinging open violently.
To open the door from the outside, unlock it with the key
provided and press the lock barrel A to release the catch.
A
Close the door from the inside by pulling the closing bar B
firmly; it will latch itself.
378510
To open the door from the inside, push lever C forwards to
release the catch.
B
C
Ventilation of Optional Glazed Cab

378520
Maximum ventilation can be achieved by removing the
front screen.
! CAUTION
The front screen is heavy. Removal and refitting of the
front screen should be done by two people, one on
either side of the machine.
3-2-1-4 E D
1 Fully Lower the Loader Arm and Stop the Engine E E
2 Remove the Windscreen Wiper Arm and Blade E
3 Remove the Front Screen
a Remove the seven thumbscrews D (inside the

E E
cab).
b Support the screen and remove the seven clamps
E (outside the cab). E
c Carefully lift the front screen clear of the machine. E
d Store the front screen, wiper arm and blade safely
to prevent damage. 378150
Note: Early machines had only three securing clamps.
Fitting is a reversal of the removal procedure. Fully lower

the loader arm and stop the engine before fitting the front
screen.
4320-3

24
OPERATION 24
EMERGENCY EXITS
! WARNING Machines with Optional Glazed Cab

The ROPS/FOPS cab is designed to give you
protection in an accident. If you do not wear your seat This type of cab provides the following escape routes:
belt, you could be thrown about inside the cab, or
thrown out of the machine and crushed. You must 1 Cab Door
wear a seat belt when using the machine. Fasten the
seat belt before starting the engine. (see 1 in Machines with Unglazed Cab).
2-2-1-9
2 Front Screen Aperture
When the machine comes to rest following an accident,
switch the starter key to the OFF position, if at all possible, (see 2 in Machines with Unglazed Cab). To escape
and remove the seat belt. via this route it is necessary to remove the screen.
Release the seven thumbscrews D inside the cab to
It is important to be aware of the exit routes available to free the securing clamps E. If help is at hand, the
you if your machine is involved in an accident. screen can then be lifted clear. (See Ventilation of
Optional Glazed Cab). If no help is available the
The alternative routes depend upon the cab specification. screen can be pushed clear from inside the cab.
Choose your route carefully to make sure it does not
expose you to any danger. Note: Early machines had only three securing clamps.
Machines with Unglazed Cab

This type of cab provides the following possible escape
routes:
E D
1 Cab Door
E E
If the machine is still upright and the door is
unobstructed, this is the best way out since it
E
provides both a footrest and handrails. If the machine
has overturned, the door should be considered along
with the alternative route below, according to the
circumstances. E E
2 Front Screen Aperture
E
This is the alternative way out.
E
378150
4320-3

25
OPERATION 25
SEAT AND SAFETY RESTRAINT
Seat Adjustment
The operator's seat can be adjusted forwards or
backwards for comfort. A correctly adjusted seat will
reduce operator fatigue. Position the seat so that you can
comfortably reach the controls.
1 High Back Seat

Move handle A to the right and slide the seat forwards
or backwards to the required position.
Suspension Seat
Lift handle A upwards and slide the seat forwards or
backwards to the required position.
2 Release handle A and make sure the seat locks into

position.
Seat Removal/Replacement
It may be necessary to remove the operator's seat in order
to gain access to the hydraulic pumps and motors. A
1 Raise the Safety Restraint Bar.
2 Release the two turnbuckles B securing the seat base B B 323900

to the pump cover. The seat and base can then be
lifted clear.
3 To replace the seat, position the seat base over the

pump cover aperture, locating the lug at the back into
its bracket. Lower the seat base into position then
secure the turnbuckles to lock the seat base to the
pump cover. Make sure the seat is secure before using
the machine.
Safety Restraint
To prevent the controls being accidentally operated when
the driver is entering or leaving the cab, the machine is
equipped with a Safety Restraint Bar C.
The safety restraint bar is arranged so that the driver is

physically prevented from entering or leaving the cab
unless the restraint bar is raised, out of the way. With the
restraint in the raised position, the brakes are applied and
the transmission and loader controls are prevented from
operating.
C
Once the driver is correctly seated and there is no danger
of the control levers being inadvertently moved, the Safety
Restraint Bar should be lowered until it latches, in
readiness for operation.
332770
Prior to leaving the cab, lift the Safety Restraint bar fully
upwards.
4320-2

26
OPERATION 26
CONTROLS, SWITCHES AND INSTRUMENTS
Cab Layout - Servo Machines
8 6
9 7
$
£
@ 4 3
1
0
^
378430
378460
4320-1

27
OPERATION 27

(continued)
Cab Layout - Servo Machines (cont’d)

1 Left Hand Control Lever (single lever drive control) 9 Hourmeter
The lever controls forward/reverse drive and steering. With the starter switch in the IGN position, shows the
It is spring loaded to its central (neutral) position. See total running time of the engine. Use it to keep a
Driving the Machine. check of running hours between maintenance
intervals.
Left Hand Control Lever (dual lever drive control)
The lever performs two functions: forward/reverse 10 Heater Air Vents (optional)
drive of the left hand wheels and arm lift and lower. It See Cab Heater Unit.
is spring loaded to its central (neutral) position. See
Driving the Machine and Loader Controls. 11 Auxiliary Attachments Control
See Loader Controls.
2 Right Hand Control Lever (single lever drive control)
The lever controls arms lift and lower and bucket open 12 Horn Push
and close. It is spring loaded to its central (neutral) Press the button to sound the horn.
position. See Loader Controls.
13 Two Speed Drive Button (optional)
Right Hand Control Lever (dual lever drive control) Press button to select high speed forward drive.
The lever performs two functions: forward/reverse Warning light illuminates when high speed is selected.
drive of the right hand wheels and shovel dump and (See Warning Indicators). High speed drive will
crowd. It is spring loaded to its central (neutral) remain selected until the button is pressed again or if
position. See Driving the Machine and Loader the ignition is switched off.
Controls.
! CAUTION
! CAUTION Do not switch from high to low speed whilst the
Do not attempt to operate the machine immediately machine is travelling quickly otherwise the machine
after starting in cold conditions, i.e. 5°C (20°F). The will slow suddenly.
machine may not respond properly to control 0069
movements. Allow at least 10 minutes warm up time
with the engine at half throttle. Operate the arm and ! CAUTION
shovel services to warm the hydraulic oil. On machines with 2 speed drive motors, do not select
3-1-1-5/1
high speed when wheel mounted tracks are fitted as
this could cause tyre damage.
3 Safety Restraint Bar 0092
See Safety Restraint.
14 Fuse Box
4 Hand Throttle Lever See Fuses in MAINTENANCE section.
Once the engine has started, set the lever to give an
engine speed suitable for the conditions and 15 Pod Switches
operations to be performed. See Switches.
5 Throttle Foot Pedal (optional) 16 Windscreen Washer Bottle (optional)

This control can be used to increase the engine speed Contains the screen washing fluid for the front screen.
by overriding the setting of the hand throttle lever. For Windscreen Wash/Wipe Switch see Switches.
When the pedal is released the engine speed reverts
to that set by the hand throttle lever.
6 Instrument Panel
See Switches, Warning Indicators.
7 Starter Switch
See Starting the Engine.
8 Fuel Gauge
With the starter switch in the IGN position, shows the
amount of fuel left in the tank.
4320-2

28
OPERATION 28

(continued)
Cab Layout - Manual Machines
8 6
9 7
2
£
$
!
4 3
1
0
^
378440
5 @
378460 378470
4320-1

29
OPERATION 29

(continued)
Cab Layout - Manual Machines (cont’d)

1 Left Hand Control Lever 10 Heater Air Vents (optional)
The lever performs two functions: forward/reverse See Cab Heater Unit.
drive of the left hand wheels and arm lift and lower. It
is spring loaded to its central (neutral) position. See 11 Horn Push
Driving the Machine and Loader Controls. Press the button to sound the horn.
Note: When the optional Loader Control Pedals are 12 Loader Control Pedals (optional)
fitted (see item 12), this lever controls the left hand The left hand pedal controls arms lift and lower and
forward/reverse drive only. the right hand pedal controls shovel dump and crowd.
See Loader Controls.
2 Right Hand Control Lever
The lever performs two functions: forward/reverse 13 Two Speed Drive Button (optional)
drive of the right hand wheels and shovel dump and Press button to select high speed forward drive.
crowd. It is spring loaded to its central (neutral) Warning light illuminates when high speed is selected.
position. See Driving the Machine and Loader (See Warning Indicators). High speed drive will
Controls. remain selected until the button is pressed again or if
the ignition is switched off.
Note: When the optional Loader Control Pedals are
fitted (see item 12), this lever controls the right hand ! CAUTION
forward/reverse drive and the Auxiliary Attachments.
Do not switch from high to low speed whilst the
machine is travelling quickly otherwise the machine
3 Safety Restraint Bar
will slow suddenly.
See Safety Restraint. 0069
4 Hand Throttle Lever ! CAUTION

Once the engine has started, set the lever to give an
engine speed suitable for the conditions and On machines with 2 speed drive motors, do not select
operations to be performed. high speed when wheel mounted tracks are fitted as
0092
5 Throttle Foot Pedal (optional)
This control can be used to increase the engine speed
14 Fuse Box
by overriding the setting of the hand throttle lever.
See Fuses in MAINTENANCE section.
When the pedal is released the engine speed reverts
to that set by the hand throttle lever.
15 Pod Switches
See Switches.
6 Instrument Panel
See Switches, Warning Indicators.
16 Windscreen Washer Bottle (optional)
Contains the screen washing fluid for the front screen.
7 Starter Switch
For Windscreen Wash/WipeSwitch see Switches.
See Starting the Engine.
8 Fuel Gauge
amount of fuel left in the tank.
9 Hourmeter
total running time of the engine. Use it to keep a
check of running hours between maintenance
intervals.
4320-2

30
OPERATION 30

(continued)
Switches Pod Mounted Switches

Each switch has an insert with a graphic symbol. This The following switches are mounted on a pod on the right
symbol and the switch descriptions are detailed below. hand side of the cab.
Parking Brake
Instrument Panel Switches
Two position rocker switch with sliding lock. Press down
The following switches are mounted on the overhead to apply the brake. Slide lock then press up to release the
instrument panel. brake. Warning light illuminates when the brake is
switched on. (See Warning Indicators).
Front and Rear Work Lights
Two position rocker switch. Press down to
switch on the front work lights. Press down
again to switch on the rear worklights. Press P P
up to switch off.
! WARNING 382150
Do not drive on the road with the work lights switched

on. You can dazzle other drivers and cause an With the switch in the off position, the machine’s brakes
accident. are automatically released whenever the engine is started
2-2-2-5
due to hydraulic system pressure. When the engine is
Note: If the roadlight kit is fitted to the machine the front stopped the brakes are automatically applied.
work lights are replaced by the front roadlights. Also the
front and rear worklight switch is replaced with a rear Note: The brakes will also be applied while the engine is
worklight switch. running if the Safety Restraint is raised.
Windscreen Wipe/Wash (optional) The switch is used to apply the brakes while the engine is
Two position rocker switch. Press down to running when certain static attachments are being used
switch on the windscreen wiper. Press again e.g. auger.
to direct the washer fluid onto the
windscreen. The washer switch is spring The switch can also be used to apply the brakes in an
loaded and returns to the wiper on position emergency to stop the machine almost instantly.
when released. Press up to switch off wiper.
Note: Such usage should only be undertaken as a last
Road Lights (optional) resort since the brake mechanism can be damaged. Get
Two position rocker switch. Press down to the brakes checked after an emergency stop.
switch on the side and tail lights. Press
down again to switch on the headlights. High-flow Hydraulics (optional)
Press up to switch off. Two position rocker switch with sliding lock. Slide lock
! CAUTION and press down to activate High-flow circuit. Press up to
deactivate circuit.
It is illegal to travel on public highways without proper
road lights. DO NOT take the machine on public
highways unless it is equipped with the optional road
light kit.
3-2-1-1
Beacon (optional)
382160
Rocker switch. Press to switch on the
beacon. Press up to switch off. (See
Rotating Beacon).
Note: High-Flow hydraulics will not operate if the engine
speed is too low.
Hazard Warning Lights (optional)
Rocker switch. Press down to switch on the
hazard warning lights. Press up to switch
off.
4320-1

31
OPERATION 31

(continued)
Pod Mounted Switches (cont’d)

Direction Indicators (optional) 4 Hydraulic Oil Temperature High
A 3-position rocker switch. From its central
OFF position, press left or right to indicate Lights if the hydraulic oil temperature rises too far.
corresponding direction of turn. The switch
is manually reset to its central (neutral) 5 Low Hydraulic Charge Pressure
position.
Lights if the hydraulic charge pressure drops too far.
The light should go out when the engine starts. If this
Self Level (optional)
light remains on stop the engine immediately.
Rocker switch. Press down to switch on self
SERIOUS TRANSMISSION DAMAGE COULD OCCUR
level function. Press up to switch off. Switch
IF THIS WARNING IS IGNORED.
illuminates when self level is switched on.
Note: A blocked hydraulic oil filter is a possible cause of
low hydraulic charge pressure.
Heater Blower (optional)
Three position rocker switch. (See Cab When the following indicators are illuminated, there is no
Heater Unit). audible warning.
6 Air Filter Blocked

Float Control (optional) - servo only Lights if the engine air filter is blocked.
Rocker switch. (See Float Control)
7 Parking Brake
Lights when the parking brake is manually engaged

(see note below).
Warning Indicators 8 High Speed Drive
When the following indicators are illuminated, an audible Lights when high speed drive is selected (see note
warning is also activated. below).
! CAUTION Note: On early machines the Parking Brake and High

If any audible/visual warnings operate whilst the Speed warning lights are located on the switch pod.
engine is running, stop the engine as soon as it is safe
to do so and rectify the fault.
4-2-1-2
1 No Electrical Charge
Lights when the starter switch is set to IGN before - +

starting the engine. The light should go out a few 1 2 3
seconds after the engine starts. Also lights if the
battery charging circuit fails while the engine is
running. 6 5 4
2 Engine Oil Pressure
Lights if the engine oil pressure drops too far. The

light should go out when the engine starts. If this light
remains on stop the engine immediately. SERIOUS
ENGINE DAMAGE COULD OCCUR IF THIS
WARNING IS IGNORED. 7 8
3 Water Temperature High
P
Lights if the engine coolant overheats. This warning 382190
light will also illuminate if the coolant level falls too far.
4320-1

32
OPERATION 32
SEAT BELT
! WARNING
Do not use a seat belt which is damaged or
excessively worn.
Do not use a seat belt that has been in an accident.
A worn, damaged or already stressed seat belt could

break or give way in a collision. If that happens you B
could be killed or injured.
2-2-3-8 A
! WARNING
Operating the machine without a seat belt can be
dangerous. Before starting the engine, make sure your
seat belt is fastened. Check the tightness and
condition of the seat belt securing bolts regularly (see
maintenance schedules).
INT-2-1-8/1
Fastening the Seat Belt

1 Sit correctly in the seat. Remove the male fitting A
from its stowage and position it across your lap.
2 Push the male fitting A into the buckle B until it

latches into position. Make sure the seat belt is not 106842
twisted.
Note: If the belt 'locks' before the male fitting A has been
engaged, allow the belt to fully retract in its reel holder and
then try again. The inertia mechanism may lock if you pull
the belt too sharply or if the machine is parked on an
incline. In such cases, ease the belt gently from its reel
holder.
A
Releasing the Seat Belt
1 Press button C and pull the male fitting A from the
buckle B. C
2 Let the seat belt retract into its reel holder.
106842
3 Replace male fitting A in its stowage.
Checking Seat Belt Operation

1 Sit correctly in the seat and fasten the seat belt as
described.
2 Take hold of the seat belt and tug. The seat belt
should 'lock'.
If the seat belt does not 'lock' when the above test is
performed, get the seat belt repaired or replaced.
106842
4320-1

33
OPERATION 33
CAB HEATER UNIT (OPTIONAL)
The self-contained heater unit, when fitted, is located just

below the windscreen.
The heater fan can only be operated with the starter switch
at IGN. There is a three position rocker switch A on the
right hand pod.
Switch Positions
1 OFF 1 2 3
2 ON (slow)
3 ON (fast)
Two air vents, one to the windscreen B and one to the floor
A
of the cab C, direct the air flow. The floor vent has a
manually operated on/off control D.
The heater unit can be used to blow either cold or hot air. B
Valve E is used to regulate the flow of engine coolant
through the heater unit. The lever should be in position X
for cold air, in position Y for hot air, or to its mid-position
for warm air. C
! WARNING
The engine has exposed rotating parts. Do not open
the engine cover while the engine is running. Do not E
use the machine with the cover open.
INT-2-1-6/1 D
! WARNING
Beware of the hot exhaust system even with the
engine stopped. Y X
ENG 4-3
378450
4320-1

34
OPERATION 34
CAB INTERIOR LIGHT (OPTIONAL)
Press on the end of the light lens to switch on the cab

interior light. Press on the opposite end of the lens to
switch off the interior light.
Note: The interior light must be turned off after use, as it is

permanently live, even when the Starter Switch is set to
OFF.
329980
LOADER CONTROLS - SERVO MACHINES
Loader Arm/Shovel Control Lever

(single lever drive control) 3
The right hand lever controls the movement of the loader
arm and the shovel (or any other attachment which is
installed on the loader arm). 2
The lever has four main movements and is spring-loaded
to its central (hold) position.
1
The speed of loader/shovel movement depends on how
far you move the lever; the further you move the lever the 4
faster the action.
The main lever movements are shown right. Their effects

are described below. Combined actions can be achieved
by moving the lever diagonally. 378570
1 To raise the loader arm pull the lever back.
2 To lower the loader arm, push the lever forward.
3 To roll the shovel forward (dump), push the lever to 1

the right.
4 To roll the shovel back (crowd), push the lever to the

left. 4
! CAUTION
Do not attempt to operate the machine immediately
after starting in cold conditions, i.e. -5°C (20°F). The
machine may not respond properly to control
with the engine at half throttle. Operate the arm and 3
shovel services to warm the hydraulic oil.
3-1-1-5/1 2 378200
4320-2

34A
OPERATION 34A

(continued)
Loader Arm Control

(dual lever drive control) 2
The loader arm is raised or lowered by lateral movement of
the left hand control lever.
The lever is spring-loaded to its central (hold) position.
The speed of loader arm movement depends on how far

you move the lever; the further you move the lever the
faster the action.
1
The lever movements are shown right. Their effects are
described below.
1 To raise the loader arm push the lever to the left.

398770
2 To lower the loader arm push the lever to the right.
Shovel Control 1
(dual lever drive control)
The shovel is opened or closed by lateral movement of the 4
right hand control lever.
The speed of shovel movement depends on how far you

move the lever; the further you move the lever the faster
the action. 3
described below.
2 378200
3 To roll the shovel forward (dump) push the lever to the

right.
4 To roll the shovel back (crowd) push the lever to the 3

left.
! CAUTION
after starting in cold conditions, i.e. -5°C (20°F). The
movements. Allow at least 10 minutes warm up time 4
with the engine at half throttle. Operate the arm and
3-1-1-5/1
398760
4320-1

35
OPERATION 35

(continued)
Auxiliary Attachments Control Pedal

(optional)
A four position rocker pedal A is used to actuate the
hydraulic function of an attachment. Press on either the
top (toe) or bottom (heel) of the pedal to operate the
attachment. The pedal is spring loaded to the central OFF
position. A detent position is provided for attachments A
which require continuous operation, i.e. Sweeper. Refer to B
OPTIONAL ATTACHMENTS section or, if appropriate, the
instructions supplied with the attachment, for details of the
function controlled.
The pedal is fitted with a lock to prevent accidental

operation. Slide the lock B to the left to secure the pedal in
the central OFF position.
378460
! WARNING
The auxiliary attachments control pedal must be locked
in its centre OFF position when no attachments are
fitted. Otherwise damage to the hydraulic system can
result due to overheating. Always engage the lock
BEFORE leaving or entering the cab.
3-2-1-12
Float Control Switch (optional)

This option allows the loader arm and shovel to 'float'.
When selected the shovel is free to ride up and down over
the ground as the machine travels.
! CAUTION
If Float is selected with the loader raised, the loader
will descend to ground level and 'float' across it as you
travel. You will not have control over the rate of fall.
2-2-2-7
Always lower the loader to the ground before selecting

Float.
Press the switch to select Float. The switch is spring

loaded to the OFF position. Float will be automatically 332812
deselected when the arms raise control is operated.
4320-1

36
OPERATION 36
LOADER CONTROLS - MANUAL MACHINES
Loader Arm Control - Lever Option

3
On manual machines the loader arm is raised or lowered
by lateral movement of the left hand control lever. 2
The speed of loader arm movement depends on how far

you move the lever; the further you move the lever the
faster the action.

described below. 1
1 To raise the loader arm push the lever to the left.
2 To lower the loader arm, push the lever to the right. 332831
3 To select float, push the lever further to the right into

the detent position.
Note: When float is selected the bucket is free to ride up

and down over the ground as the machine travels. 1
! CAUTION
If Float is selected with the loader raised, the loader 5
2-2-2-7
Always lower the loader before selecting Float.
4
3 2 378200
Shovel Control - Lever Option

On manual machines the shovel is opened or closed by
4
lateral movement of the right hand control lever.
The speed of shovel movement depends on how far you

move the lever; the further you move the lever the faster
the action.

described below.
5
4 To roll the shovel forward (dump), push the lever to the
right.
5 To roll the shovel back (crowd), push the lever to the 332840
left.
4320-1

37
OPERATION 37
LOADER CONTROLS - MANUAL MACHINES

(continued)
Loader Arm/Shovel Control - Pedal Option

4
With this option on manual machines the loader arm is
raised or lowered by movement of the left hand control
pedal.
The shovel is opened or closed by movement of the right

23
hand control pedal. 5
The pedals are spring-loaded to their central (hold)
position.
The speed of loader movement depends on how far you

press the pedals; the further you press the pedals the 1
faster the action.
The pedal movements are shown right. Their effects are

described below.
1 To raise the loader arm push the bottom of the left 378470
hand pedal.
2 To lower the loader arm, push the top of the left hand
pedal.
3 To select float, push the top of the left hand pedal

1
further into the detent position.
Note: When float is selected the bucket is free to ride up 5

and down over the ground as the machine travels.
! CAUTION
If Float is selected with the loader raised, the loader
2-2-2-7 4
Always lower the loader before selecting Float. 3 2 33031
4 To roll the shovel forward (dump), push the top of the

right hand pedal.
5 To roll the shovel back (crowd), push the bottom of the

right hand pedal.
A
Auxiliary Attachments Control (optional)

The right hand control lever A is used to actuate the
hydraulic function of an attachment. Move the lever either
to the right or left to operate the attachment. The lever is
spring loaded to the central OFF position. Refer to
OPTIONAL ATTACHMENTS section or, if appropriate, the
instructions supplied with the attachment, for details of the
function controlled.
332840
A detent position may also be provided for attachments

which require continuous operation, i.e. Sweeper.
4320-1

38
OPERATION 38
BEFORE STARTING THE ENGINE
Note: Read Operating in Low Temperatures or

Operating in High Temperatures if you will be using the ! WARNING
machine in very cold or very hot climates. Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
1 Do a Pre-Start Inspection accident. Fit a new seat belt every three years
regardless of condition.
For your own safety (and others') and for maximum 2-3-1-8
service life of your machine, do a pre-start inspection
before starting the engine. h Inspect the seat belt and its mountings for
damage and excessive wear.
a If you haven't already done it, do a walk round
inspection of the outside of the machine (see i Check that the following (as applicable) are in
Before Entering the Cab). working order:
Lights, warning lights, rotating beacon, direction
b Remove dirt and rubbish from the cab interior, indicators, all switches, windscreen washer and
specially around the pedals and control levers (see wipers.
Cleaning the Cab Interior in MAINTENANCE
section). Do the following after entering the machine.
2 Close and Latch the Door.

! WARNING
Keep the machine controls clean and dry. Your hands 3 Lower the Safety Restraint Bar
and feet could slide off slippery controls. If that
happens you will lose control of the machine. Ensure that the Restraint Bar is in the correct position
2-2-3-6 and locked.
c Remove oil, grease and mud from the pedals and 4 Adjust the Seat
control levers.
Adjust the seat (see Seat Adjustment), so that you
d Make sure that your hands and shoes are clean can comfortably reach all the operating controls.
and dry. (See WARNING above.)
5 Fasten and Adjust the Seat Belt
! CAUTION 6 Ensure the Drive Control is in Neutral

Loose articles can fall and strike you or roll on the
floor. You could be knocked unconscious, or the If the engine is started with the drive control deflected
controls could get jammed. If that happens you will to either the forward or reverse position the machine
lose control of the machine. will lurch forward or backwards. The control is spring
2-2-3-7/1 loaded to return to neutral, but ensure that nothing has
caused the lever(s) to be deflected.
e Remove or secure all loose articles in the cab -
such as lunch boxes, tools etc.
f Inspect the ROPS/FOPS structure for damage.

Get your JCB distributor to repair or replace the
structure if damaged.
g Check round the cab for loose or missing bolts,

screws etc. Replace or tighten where necessary.
4320-1

39
OPERATION 39
STARTING THE ENGINE
Note: Read Before Starting the Engine on the previous Note: The starter should be operated for no longer than 20
page before starting the engine. seconds at a time. If the engine fails to start, allow the
starter to cool for a few minutes before trying again.
1 On servo machines, ensure that the Drive Control
Lever A is in the neutral position (see Step 6 on 5 As soon as the engine starts, release the key which
previous page). will return to the IGN position.
Note: On machines fitted with dual lever drive controls, the Note: Make sure all the warning lights are OFF when the
Drive Control is operated by both left and right hand levers. engine is running.
On manual machines, ensure that the Drive Control If any warning lights remain on, stop the engine
Levers E and F are in the neutral position (see Step 6 immediately and investigate the cause.
on previous page).
6 Once the engine has warmed up, set the Hand
2 Switch the High-flow circuit off (if fitted). The engine Throttle Lever to the required speed.
will not start if the High-flow circuit is switched on.
! CAUTION
3 Slightly depress the accelerator pedal (if fitted) or set Do not attempt to operate the machine immediately
the Hand Throttle Lever B to fast idle position. after starting in cold conditions, i.e. -5°C (20°F). The
4 Turn the Starter Key C fully clockwise against the movements. Allow at least 10 minutes warm up time
spring to position HS to start the engine. with the engine at half throttle. Operate the arm and
Note: If weather conditions are cold it may be necessary to 3-1-1-5/1
use the pre-heat position. Turn the starter key clockwise
partially to H and hold against the spring pressure for 10-15
seconds then turn the key fully clockwise to HS to start the
C C
B B
E
378430 378440
engine.
4320-2

40
OPERATION 40
JUMP-STARTING THE ENGINE
! WARNING
In temperatures below freezing, the battery electrolyte d Connect the other end of this cable to the
may freeze if the battery is discharged or poorly negative (-) terminal on the booster supply.
charged. Do not use a battery if its electrolyte is
frozen. To prevent the electrolyte from freezing, keep 3 Do the Pre-Start Checks
the battery at full charge.
See Steps 2 to 6 of Before Starting the Engine.
Do not try to charge a frozen battery, or jump-start
and run the engine, the battery could explode. 4 Start the Engine
Batteries produce a flammable gas which is explosive; See Starting the Engine.
do not smoke when checking the electrolyte levels.
5 Disconnect the Booster Cables
When jump-starting from another vehicle, make sure
the two vehicles do not touch each other. This a Disconnect the negative booster cable from the
prevents any chance of sparks near the battery. machine earth. Then disconnect it from the
booster supply.
Switch off all circuits which are not controlled by the
starter switch. b Disconnect the positive booster cable from the
positive (+) terminal on the battery. Then
Do not connect the booster (slave) supply directly disconnect it from the booster supply.
across the starter motor.
c Lower and lock the engine compartment top cover.
Use only sound jump-leads with securely attached
connectors. Connect one jump-lead at a time.
The machine has a negative earth electrical system.

Check which battery terminal is positive (+) before
making any connections.
Keep metal watch straps and jewellery away from the

jump-lead connectors and the battery terminals - an
accidental short circuit could cause serious burns and
damage equipment.
Make sure you know the voltage of the machine. The

booster (slave) supply must not be higher than that of
the machine. Using a higher voltage supply will
damage your machine’s electrical system.
If you do not know the voltage of your booster (slave)

supply, then contact your JCB dealer for advice. Do
not attempt to jump-start the engine until you are sure
of the voltage of the booster (slave) supply.
8-2-7-4/1
1 Set all Switches In the Cab to Off
2 Connect the Booster Cables
a Raise the engine compartment top cover.
b Connect the positive booster cable to the positive

(+) terminal on the machine battery. Connect the 378540
other end of this cable to the positive (+) terminal
of the booster supply.
c Connect the negative (-) booster cable to a good

earth on the machine, away from the battery (e.g.
one of the engine cover hinge brackets).
4320-1

41
OPERATION 41
ROTATING BEACON (OPTIONAL)
The rotating beacon has a magnetic base for securing it to

the roof of the cab. It plugs into jack socket under the
front of the cab roof at A.
The socket is protected by a hinged cap which lifts for

A
fitting the jack plug. Press the beacon switch to turn the
beacon on or off.
Note: After removing the plug, the cap will be closed by

the spring hinge.
Note: DO NOT leave the beacon on the cab roof when not
in use. Return it to its storage position.
378220
TRAVELLING POSITION
! WARNING Travelling on Public Roads

A high loader shovel can block your view and reduce
the stability of the machine. Travel with the loader low ! CAUTION
to the ground. Travel slowly and with caution over It is illegal to travel on public highways without proper
rough, muddy or loose surfaces. road lights. DO NOT take the machine on public
2-1-1-3
highways unless it is equipped with the optional road
light kit.
Note: Some attachments may require different travel 3-2-1-1
positions to those described below. See OPTIONAL
ATTACHMENTS or the instructions supplied with the
attachment.
! WARNING
Do not drive on the road with the work lights switched
on. You can dazzle other drivers and cause an
accident.
Travelling on Site 2-2-2-5
1 Lower the loader arm to its lowest position B. 1 Carry out Steps 1 and 2 of On Site.
2 Roll back (crowd) the shovel or other attachment C. 2 Fit and plug-in the rotating beacon, if available.
Note: In some circumstances a rotating beacon is a legal

requirement for travelling on public roads.
C
378290
4320-1

42
OPERATION 42
TRAVELLING POSITION
(continued)
Travelling on Public Roads (UK only)

In the U.K., before travelling on public roads, it is your
responsibility as a user to comply with The Road Vehicles
(Construction and Use) (Amendment) Regulations 1997
(“Bridge Bashing Regs.”). By way of guidance only, the
following steps may be taken to comply:
1 Always assess your route for overhead structures

such as bridges which could be damaged by your
machine.
2 Utilise the restraint device (described below) to ensure

that the equipment is in the travelling position.
IMPORTANT NOTE: Whilst this information is believed to

be correct, JCB cannot be aware of all circumstances in
which JCB machines may be operated on a Public A
Highway and it is the responsibility of the user to ensure
compliance with the regulations.
378420
Machines without Float Option
1 Carry out Steps 1 and 2 of Travelling on Public

Roads.
2 Make sure the Loader arm is fully lowered. B

3 Open the engine compartment top cover. (see Engine
Compartment Access.)
4 Move lever A in the direction shown to prevent the

arm from being raised.
5 Close the engine compartment top cover.
Reverse the above operation to allow the machine to be

used on site.
Machines with Float Option
1 Carry out Steps 1 and 2 of Travelling on Public

Roads.
334110
2 Make sure the Loader arm is fully lowered.
3 Remove the floor plate.
4 Push in knob B and turn clockwise to lock in position.

This will manually select the float position and prevent
the arm from being raised.
5 Replace the floor plate.
Reverse the above operation to allow the machine to be

used on site.
4320-1

43
OPERATION 43
DRIVING THE MACHINE
Before attempting to drive the machine, read the

Operating Practices and WARNINGS first.
Drive Control Lever

(servo single lever drive control)
The machine is driven by use of the Drive Control Lever A.
This lever performs two functions: forward/reverse drive
and steering. It is spring loaded to its central (neutral)
position.
Forward/Reverse Drive. Starting from the neutral position,

select forward drive by pushing the lever forwards as at B,
or select reverse drive by pulling the lever back as at C.
The amount of lever movement controls the speed of the
machine; the greater the movement the faster the speed. A
An optional reverse alarm is available. When reverse is
selected the alarm automatically sounds to warn passers-
by. 378560
Steering is achieved in both forward and reverse drive (i.e.

with the lever forward or back). By moving the lever
forward and to the left as at D the machine will steer to the
left. By moving the lever forward and to the right as at E B
the machine will steer to the right. The greater the travel of D E
the lever, the sharper the turn will be.
By moving the lever back and to the left as at F the

machine will reverse and steer to the left. By moving the
lever back and to the right as at G the machine will reverse
and steer to the right.
The machine can also be turned round (spin turn) within its H J
own length. To spin turn to the left as at H, move the lever
from the neutral position to the left. To spin turn to the
right as at J, move the lever from the neutral position to
the right.
Avoid excessive or too rapid movements of the lever F G

which could cause the machine to become unstable. C 330020
Return the lever to the central position when the
manoeuvre is complete.
B
D E
H J
F G
C 330050
4320-2

44
OPERATION 44
DRIVING THE MACHINE

(continued)
Before attempting to drive the machine, read the

Operating Practices and WARNINGS first.
Drive Control Levers

(servo dual lever drive & manual controls)
Note: The illustration shows a manual control machine. B
The machine is driven by use of the left and right drive
control levers, A and B. The levers are spring loaded to
their central (neutral) positions.
Forward/Reverse Drive. Select forward drive by pushing

both levers forward (C, D) or select reverse drive by pulling
the levers back (E, F). The amount of lever movements A
control the speed of the machine; the greater the
movement the faster the speed. Move both levers by the
same amount so that the machine moves in a straight line.
An optional reverse alarm is available. When reverse is

selected the alarm automatically sounds to warn passers-
by. 332822
Steering is achieved in both forward and reverse drive. To

turn left in forward drive, move the right hand lever
forwards as at D. The greater the travel of the lever, the
CD
sharper the turn will be. To turn right, move the left hand D C
lever forwards as at C.
To turn left in reverse drive, move the left hand lever back
as at E. To turn right in reverse, move the right hand lever
back as at F.
Turns can also be achieved whilst the machine is moving D C

either in forward or reverse by easing back the appropriate
lever towards the neutral position. E F
The machine can also be turned round within its own
length (spin turn). To turn anti-clockwise move the right
hand lever forwards as at D and the left hand lever back
as at E. To turn clockwise move the right hand lever back F E
as at F and the left hand lever forwards as at C. EF 330020
Avoid excessive or too rapid movements of the levers

which could cause the machine to become unstable. C D
Return the levers to their central positions when the
manoeuvre is complete.
A B
E F 330060
4320-2

45
OPERATION 45
DRIVING THE MACHINE

(continued)
Getting Moving Stopping and Parking

Before attempting to drive the machine, read the Where possible, choose dry, level ground to stop the
Operating Practices and WARNINGS first. machine. If it is necessary to park on a slope, position the
machine at right angles to the slope and block the wheels
1 Check your Seat and Seat Belt to prevent movement. NEVER PARK ON A STEEP SLOPE.
Make sure that the seat is correctly adjusted. Make 1 Stop the Machine
sure that your seat belt is correctly fastened and
adjusted. Ease the Drive Control Lever(s) to the neutral position
to bring the machine smoothly to rest.
2 Lower the Safety Restraint
! DANGER
Lower the Safety Restraint Bar until it latches.
Before lowering the attachments to the ground, make
3 Start the Engine sure that the machine and the area around it are clear
of other people. Anyone on or near the machine could
Start the engine and set the Hand Throttle Lever (see fall and be crushed by the attachments, or get caught
Starting the Engine). in the linkages.
2-2-3-4
4 Select Forward/Reverse to Move Off 2 Lower the Attachment to the Ground

a Check that the shovel/attachment is in the travel Operate the Loader Control to bring the loader arm to
position. its lowest position.
b Make sure it is safe to move off, then slowly
operate the Drive Control Lever(s) to forward or 3 Stop the Engine
reverse as required. The machine will move
smoothly away. Turn the Starter Key to the 'Off' position. The machine
brakes are automatically applied when the engine
Note: If you are unfamiliar with the machine it is stops.
recommended that you ensure that low speed is selected
before moving off otherwise the machine speed may catch Note: If you exit the cab whilst the engine is running, leave
you unawares. Always stop the machine before changing the safety restraint raised as this applies the brake.
from low to high speed or vice versa.
4 Remove the Starter Key
! CAUTION
Do not dismount a moving machine. If you are going to leave the machine, remove the
3-2-3-12 Starter Key.
5 Switch off All Unnecessary Switches
! WARNING
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
6 Leave and Secure the Machine
See Entering/Leaving the Cab. If you are leaving the

machine unattended, close and lock the door.
4320-3

46
OPERATION 46
OPERATING PRACTICES
! WARNING ! CAUTION
Drive the machine smoothly. Avoid repeated start/stop When digging, keep the shovel horizontal. Digging with
or spin turn manoeuvres. Avoid unnecessary zig-zag the shovel tilted forward may cause damage to the
driving. shovel or the machine.
8-1-2-2 3-2-1-13
Avoid exaggerated movements of the lever(s) which could If the machine is to be used for digging, make sure that
cause the machine to go out of control through violent the lift arm bump stops A are fitted and that the arm rests
changes of speed and/or direction. against the bump stops when fully lowered.
When moving off from rest, gently move the Drive Control
Lever(s) from the neutral position. Gradually increase the
lever movement until the desired speed is reached.
! WARNING
You or others can be killed or injured if you suddenly
change from forward to reverse, or vice versa, whilst
travelling. The machine will immediately reverse
direction without warning to others. Always follow the
recommended procedure for changing between
forward and reverse drive.
3-2-1-5
When changing between forward and reverse drive,

329961
always bring the machine to rest first by progressively
moving the Drive Control Lever(s) into the neutral position.
Always negotiate a turn by gentle, progressive use of the

lever(s) until the required rate of turn is achieved, and
straighten up in the same way afterwards. Never suddenly
change from a turn in one direction to a turn in the
opposite direction.
When moving the machine, stay alert for obstructions and

possible hazards.
A
When travelling downhill, adjust the forward/reverse A
setting of the Drive Control Lever(s) to achieve a suitable,
steady speed.
385350
Remember that the Drive Control Lever(s) are like a
progressive gear lever, not a throttle, i.e. full lever travel
represents top gear. If the engine gets overloaded and
seems likely to stall, ease off the Drive Control Lever(s) to
allow the engine speed to pick up again. To spin turn, use
small lever movements (a low gear) otherwise the engine
may stall.
When overloading of the engine seems to be a recurring

problem, increase the setting of the Hand Throttle Lever if
the engine is not already running at its preset maximum
speed. If the engine is already running at its maximum
speed, reduce the load by easing off the Drive Control
Lever(s).
4320-3

47
OPERATION 47
USING THE ATTACHMENTS AND SITE SAFETY
This section explains some techniques for efficient and ! WARNING

safe use of the machine and its attachments. Attention is
You could be electrocuted or badly burned if you get
also drawn to the various safety aspects of operating on
the machine or its attachments too close to electrical
site. Read and understand this section before you start
power cables.
working with the machine. Practise using the attachments
until you are completely familiar with the controls and
You are strongly advised to make sure that the safety
what they do.
arrangements on site comply with the local laws and
Before you start using the machine, tell your work mates regulations concerning work near electric power lines.
what you will be doing and where you will be working. On
a busy site, use a signalman. Buried Electric Power Cables
Before you start using the machine, check with your
Remember that your machine is mobile. Whenever electricity supplier if there are any buried power cables
possible, manoeuvre your machine into a position which on the site.
combines safety with efficiency. If you have to choose,
remember that: Overhead Electric Power Cables
There is a minimum clearance required for working
SAFETY MUST COME FIRST beneath overhead power cables. You must obtain
details from your local electricity supplier.
Choose the correct attachment for the job. Do not use an 2-2-5-4
oversize shovel for rocky material. It could overload the
system and shorten service life. ! WARNING
! WARNING Reworking Old Sites
There could be dangerous materials such as asbestos,
Always travel with the loader arm set to its lowest poisonous chemicals or other harmful substances
position with the shovel (Quickhitch) rolled back buried on the site. If you uncover any containers or you
(crowded). A raised loader arm with a loaded shovel see any signs of toxic waste, stop the machine and
will make the machine unstable. A raised loader arm advise the site manager immediately.
will also drastically reduce your visibility. 2-2-5-5
3-1-1-2/1
! WARNING ! WARNING
Water Supplies and Drains
Work sites can be hazardous. Inspect the site before
Before you start using the machine, check with your
working on it. Look for potholes, weak ground, hidden
local public water supplier if there are buried pipes and
rocks etc. Check for utilities such as electric cables
drains on the site. If there are, obtain a map of their
(overhead and underground), gas and water pipes etc.
locations and follow the advice given by the water
Mark the positions of the underground cables and
supplier.
pipes. Make sure that you have enough clearance
beneath overhead cables and structures.
INT-2-2-1
! WARNING regulations concerning work near buried water pipes
and drains.
Before you start using the machine, inspect the job
2-2-5-6
site. 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,
! WARNING
ironwork etc. Any of these could cause you to lose Communications
control of your machine. Bad communications can cause accidents. Keep
2-2-5-2 people around you informed of what you will be doing.
If you will be working with other people, make sure any
! CAUTION hand signals that may be used are understood by
You and/or your company could be legally liable for everybody. Work sites can be noisy, do not rely on
any damage you may cause to public utilities. It is your spoken commands.
INT-2-2-3
responsibility to make sure that you know the
locations of all public utility cables or pipes on the site
which could be damaged by your machine.
2-2-5-3
4320-1

48
OPERATION 48
USING THE ATTACHMENTS AND SITE SAFETY

(continued)
! WARNING ! WARNING
Underground Gas Pipes Hillsides
Before you start using the machine, check with your Operating the machine on hillsides can be dangerous
local gas supplier if there are any buried gas pipes on if proper precautions are not taken. Ground conditions
the site. can be changed by rain, snow, ice etc. Check the site
carefully.
If there are buried gas pipes we recommend that you
ask the gas company for any specific advice regarding Going uphill, reverse when unloaded or travel forwards
the way you should work on the site. when loaded. Going downhill, travel forwards when
unloaded or reverse when loaded.
Some modern gas pipes cannot be detected by metal
detectors, so it is essential that an accurate map of Take special care when moving across a slope. If the
buried gas pipes is obtained before any excavation slope is too steep your machine could roll over. If you
work commences. must drive across a slope, keep the attachments close
to the ground.
Hand dig trial holes to obtain precise pipe locations. 3-1-1-4/1
Any cast iron pipes found should be assumed to be
gas pipes until contrary evidence is obtained.
Older gas pipes can be damaged by heavy vehicles

driving over the ground above them.
LEAKING GAS IS HIGHLY EXPLOSIVE.

If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on the
site. Ban smoking, ensure that all naked lights are
extinguished and switch off any engines which may be
running.

regulations concerning work near buried gas pipes.
2-2-6-1/1
! WARNING
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.
INT-2-2-5
! WARNING
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 378300
people away.
INT-2-2-8
! WARNING
Do not dismount a moving machine.
3-2-3-12
4320-1

49
OPERATION 49
QUICKHITCH CONTROL
Engaging the Shovel/Attachments

To engage a shovel or other attachment on the Quickhitch, 6 Raised the Safety Restraint Bar and dismount from
do the following: the machine.
1 Align the machine square to the shovel/attachment. 7 Push levers fully in, as at position C, to engage the
Quickhitch locking pins D. Check that the levers have
! WARNING locked into the detents.
Do not lean out of the cab to operate the Quickhitch
levers. If the controls are moved accidentally you 8 The shovel/attachment is now locked onto the
could be killed or injured. Quickhitch.
3-4-1-8
9 If appropriate connect the attachment tail hoses to the
2 Lower the loader arm fully to bring the hitch plate A loader arm pipework (see Connecting/Disconnecting
below the level of the lips on the shovel/attachment. Hydraulic Hoses in OPTIONAL ATTACHMENTS
Move levers (one each side of hitch plate) fully out as section).
at position B.
10 Return to the cab seat and lower the Safety Restraint
3 Drive the machine slowly forward. Stop when the hitch Bar. The shovel/attachment is now ready for use.
plate A just touches the shovel/attachment.
4 Raise the loader arm and engage the hitch plate A in

the lips on the shovel/attachment. Stop the movement
as soon as the plate is engaged.
5 Move the Loader Control Lever as if to fully roll back

the shovel/attachment.
A
B
D
D 378480
4320-1

50
OPERATION 50
QUICKHITCH CONTROL
(continued)
Disengaging the Shovel/Attachments

1 Stop and park the machine on level ground. 5 If appropriate, disconnect the attachment hydraulic
hoses from the loader arm pipework (see
2 Lower the shovel/attachment to the ground. Connecting/Disconnecting Hydraulic Hoses in
OPTIONAL ATTACHMENTS section).
3 Stop the engine and relieve hydraulic circuit pressure
(see Connecting/Disconnecting Hydraulic Hoses in 6 Pull levers (one each side of hitch plate) fully out, as at
OPTIONAL ATTACHMENTS section). position B, to retract the Quickhitch locking pins D.
! DANGER 7 Return to the cab seat, lower the Safety Restraint Bar
and start the engine.
Do not retract the locking pins when the loader arm is
raised, the shovel could fall and kill or seriously injure 8 Operate the loader Control Lever as if to roll forward
someone. Only retract the locking pins after the shovel the shovel/attachment (see Loader Controls).
has been placed on the ground.
4-2-2-1
9 When the hitch plate A has disengaged from the lips
4 Raise the Safety Restraint Bar and dismount from the on the shovel/attachment, reverse the machine clear.
machine.
10 Push levers fully in, as at position C.
! WARNING
levers. If the controls are moved accidently you could
be killed or injured.
3-4-1-8
D 378490
4320-1

51
OPERATION 51
WORKING WITH THE LOADER
! WARNING On hard surfaces, as the shovel enters the pile, start

You or others can be killed or seriously injured if you rolling back (crowding) the shovel while raising the loader
operate the control levers from outside the cab. arm at the same time. This will sweep the shovel up the
Operate the control levers only when you are correctly pile, gathering material as it goes.
seated inside the cab.
INT-2-1-3 Easing back the Drive Control Lever(s) will give more
power to operate the shovel. Try to fill the shovel in one
Remember that you will be driving the machine while you pass. Half full shovels are less productive.
are using the loader. Keep alert for bystanders and
possible hazards. Stay in the correct driving position. When moving the load, roll the shovel right back to
Keep your seat belt fastened and correctly adjusted. prevent spillage.
Keep the loader arm fully down when travelling. This When you are loading from a pile of loose material, start at
increases your visibility and makes the machine more the bottom and follow up the face as shown at A.
stable. Approach the pile with the shovel level and the loader arm
fully down.
Never lower the restraint bar to the working position
unless you or someone suitably qualified is seated In tightly packed material, start at the top and work down.
correctly in the machine and the door is properly closed
and latched. When removing material from a stockpile, start at a
shovel's height from the base. Once the height of the
stockpile has been reduced, begin loading from the base.
! WARNING
When transporting a load on a slope, drive slowly and Loading a Truck
keep the load uphill of the machine. This will increase
stability. Put the truck(s) at an angle of about 45° to the pile, as
2-1-1-5
shown at B. This cuts out unnecessary manoeuvring.
Allow enough distance for the shovel to reach its
! CAUTION unloading height while you are travelling, without slowing
If the machine should accidentally tip forward, stop the down.
engine as soon as possible and check the engine oil
level. Some oil loss can occur if this happens. Keep the wind on your back. This keeps dust away from
3-2-1-10
you and your machine.
! WARNING Move your machine as close as possible to the truck
Should the machine start to roll over, you can be
crushed if you try to leave the cab. If the machine before unloading.
starts to roll over, DO NOT TRY TO JUMP FROM THE
CAB. STAY IN THE CAB, WITH YOUR SEAT BELT If the truck body is about as long as a shovel's width, tip
FASTENED. the load into the centre of the truck. If the truck is two
INT-2-1-12 shovel-widths long or more, load the front of the truck
first.
Filling the Shovel Do not dump the material in one sudden movement. Roll
the shovel forward in stages until it is empty. Use the
! WARNING control lever to rock the shovel back and forth to loosen
When loading with material from a high bank or pile, any sticking material.
remove any overhang first. Watch out for sliding
material. If overhanging material falls, you and your Scraping and Cutting
machine could be buried.
2-2-6-3 If a deep cut is to be made, do it in steps of about 50 mm
(2 in). With the loader arm fully down, adjust the shovel
dump angle to give the desired depth of cut.
A B
326551 S174080
4320-1

52
OPERATION 52
OPERATING IN LOW TEMPERATURES
In low temperature situations, i.e. below -5 °C (20 °F), take 7 Install Cold Weather Starting Aids
the following precautions. They will make for easier
starting and prevent possible damage to your machine. In very low temperatures, i.e. below -18 °C (0 °F)
additional starting aids may be needed, for example a
1 Use the Correct Viscosity Engine Lubricating Oil coolant heater. Ask your JCB distributor for advice.
See Fluids, Capacities and Lubricants in Note: Do not connect two batteries in series to give 24
MAINTENANCE section. volts for starting. This could burn out the engine glow
plugs and starter motor.
2 Use a Low Temperature Diesel Fuel
! WARNING
If available. See Fuel System in MAINTENANCE Do not use ether or other starting fluids to assist cold
section. starting. Using these fluids may result in an explosion
causing possible injury and/or damage to the engine.
3 Use the Correct Coolant Mixture 3-2-1-9
See Engine Cooling System in MAINTENANCE 8 Remove Snow from the Engine Cover and Rear
section. Grille
4 Keep the Battery at Full Charge If the flow of cooling air is impeded, the engine could
overheat.
This helps to prevent freezing of the battery electrolyte.
! CAUTION
5 Fill the Fuel Tank at the End of Each Work Period
after starting in cold conditions, i.e. below -5°C (20°F).
The machine may not respond properly to control
This helps to prevent the formation of condensation in
the tank.
with the engine at half throttle. Operate the arm and
6 Protect the Machine When Not in Use 3-1-1-5/1
Park the machine inside a building or cover it with a

tarpaulin.
OPERATING IN HIGH TEMPERATURES
In high temperature situations, take the following 4 Keep the Radiator Clean
precautions to prevent possible damage to the machine.
Regularly remove dirt and debris from the radiator and
1 Use the Correct Viscosity Engine Lubricating Oil the engine.
See Fluids, Capacities and Lubricants in 5 Check the Alternator Belt Tension Regularly
MAINTENANCE section.
See Engine Alternator Belt in MAINTENANCE
2 Use the Correct Coolant Mixture section.
See Engine Cooling System in MAINTENANCE 6 Check the Engine Air Filter Regularly
section.
3 Check the Coolant System Regularly
Keep the coolant at the correct level. Make sure there

are no leaks.
4320-1

53
OPERATION 53
MOVING A DISABLED MACHINE
It is only possible to tow or winch the JCB Skid Steer

Loader very slowly for a short distance in a straight line.
If at all possible repair the disabled machine where it

stands. If the machine needs to be returned to the
workshop for repair, it must be winched onto a trailer or
lifted onto a truck for transportation.
Prepare the machine for towing or winching as follows.
! CAUTION A
DO NOT attempt to tow/winch the machine without
first releasing the hydrostatic braking otherwise
damage will occur to the hydraulic pumps.
3-2-1-2
A
Preparation for Towing/Winching 382890 327490
1 Block the wheels to prevent accidental movement.
2 Remove the seat and seat base. (see Seat

Adjustment & Removal/Replacement.)
3 Using an internal hexagonal wrench, loosen the four

relief valves A on the transmission pump by a
maximum of four turns.
Note: The illustration shows a servo machine but valves A

are in the same position on manual machines.
B
! CAUTION
DO NOT loosen the relief valves by more than four B
turns otherwise hydraulic fluid will be lost.
3-2-1-3 382260
X 1
4 On wheeled machines, unscrew brake cover retaining 12 3
screws B on both motors in correct sequence, as
shown at X, by one complete turn. Unscrew in 10 5
sequence by a further complete turn (max. two turns).
8 7
Note: On tracked machines it is not possible to access the
brake cover retaining screws therefore it will be necessary 6 9
to release the brakes hydraulically. Your JCB Distributor
will have the equipment to do this. 4 11
2
364350
5 Remove the wheel blocks only when the machine is
hitched up ready for towing/winching. Keep personnel
clear of the machine while the blocks are removed.
6 Tow the machine very slowly onto the trailer (see

Transporting the Machine).
After Towing/Winching
1 Tighten the four relief valves A to a torque of 55 Nm
(40 lbf ft, 5.6 kgf m).
2 Tighten brake cover screws in correct sequence, as

shown at X, a turn at a time then finally torque tighten
to 14 - 16 Nm (10 - 12 lbf ft).
4320-1

54
OPERATION 54
TRANSPORTING THE MACHINE
The safe transit of the load is the responsibility of the 4 Loading a Serviceable Machine onto the Trailer
transport contractor and driver. Any machine,
attachments or parts that may move during transit a Raise the loader arm to position the
must be adequately secured. shovel/attachment approximately 305 mm (8 in)
5-2-5-9 from the ground.
b Carefully reverse the machine onto the trailer.
Note: Make sure that the transporting vehicle is suitable. c When the machine is safely in position, lower the
See Static Dimensions in SPECIFICATIONS section for loader arm to its lowest position.
the dimensions and weight of your machine. d Switch off the engine.
e Check that the overall height of the load is within
Using a Trailer regulations. Adjust if necessary.
f Secure the cab.
! WARNING g Anchor the machine (see Transportation Safety).
Before moving the machine onto the trailer, make sure
that the trailer and ramp are free from oil, grease and
ice. Remove oil, grease and ice from the machine
tyres. Make sure the machine will not foul on the ramp
angle. See Static Dimensions in SPECIFICATIONS
section for the minimum ground clearance of your
machine.
2-2-7-5/1
1 Position the Trailer
a If the machine is disabled it will be necessary to

align the trailer with the rear of the machine.
b For an operational machine any convenient
position will be suitable.
2 Block the Trailer Wheels and Position the Ramps
a Place blocks at the front and rear of the trailer

wheels.
b Make sure the ramps are correctly in place and
secure.
3 Loading a Disabled Machine onto the Trailer 378290
The trailer must be equipped with a winch to pull the

machine aboard.
a Position the trailer as in 1a.

b Connect the winch cable to the towing hitch on
the back of the machine.
c Release the machine brakes (see Moving a
Disabled Machine).
d Operate the winch and pull the machine very
slowly onto the trailer until the shovel/attachment
is well inside the back end of the trailer.
e Secure the cab.
f Anchor the machine (see Transportation Safety).
4320-1

55
OPERATION 55
TRANSPORTING THE MACHINE

(continued)
Using a Truck Transportation Safety

Provided a crane of adequate capacity is available, it is 1 Secure the Machine
permissible to lift a machine directly onto the back of a
suitable truck. See Lifting the Machine for a safe and Make sure the lift arm is fully lowered. Close and
correct lifting procedure. secure the cab door.
2 Anchor the Machine

! WARNING
You can be injured if you use faulty lifting equipment. Put blocks at the front and rear of all four tyres, or at
Make sure that lifting equipment is in good condition. the front and rear of both tracks (if applicable). Anchor
Make sure that lifting tackle complies with all local the machine to the transporter with chains, using the
regulations and is suitable for the job. Make sure that holes C in the loader arm side plates and the towing
lifting equipment is strong enough for the job. bar D.
INT-1-3-7
3 Measure the Machine Height
! WARNING
Raised loader arms can drop suddenly and cause Measure the maximum height of the machine from the
serious injury. Before working under raised loader ground. Make sure the truck driver knows the
arms, fit the loader arm safety strut. clearance height before he drives away.
2-1-1-6
378690
4320-2

56
OPERATION 56
LIFTING THE MACHINE
Safe Lifting Procedure

! WARNING
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 F
Provided a hoist of adequate capacity is available, it is
permissible to lift a machine directly onto a suitable
transporting vehicle or hoist a machine into a new
C
operating position (eg. onto a ship or down a pit etc.).
Refer to SPECIFICATION for machine weight and

E
dimensions.
A A B
The machine must be fitted with the four approved lifting
brackets, two A at the front and two B at the rear of the
cab, secured by the correct bolts C and capscrews D. B
These brackets and fasteners are obtainable only from a
JCB Dealer. Do not use non-genuine substitutes which
may not be strong enough for the job.
Ensure that fasteners are tightened to:

Front brackets (standard bolts C) 244 Nm
Rear brackets (socket head capscrews D) 395 Nm F
Inspect the lifting brackets regularly for signs of fatigue.
D
Lift the machine using four equal length chains of
381380
adequate strength, one from each lifting bracket to a
shackle positioned centrally above the cab as shown. To
prevent unnecessary strain on the shackles and lifting
points, make sure that there is a minimum of 1.2 metres
from the cab roof to the lifting shackle as shown at E.
Make sure that hooks are fully engaged in the brackets as
at F.
Before lifting the machine into the air, take the strain and
ensure that lifting equipment is secure.
Lift and lower the machine smoothly, ensuring that there is

no fouling.
4320-2

57
OPERATION 57
EMERGENCY LOAD LOWER PROCEDURE
During normal operation, the engine must be running

before a load can be raised or lowered.
If the engine fails whilst the load is in the raised position,

the load may be lowered as follows:-
! DANGER
Do not stand underneath the raised load during the
lowering procedure. Stand clear and to one side until
the load has been safely lowered. Make sure that the
area is clear of other people before lowering the load.
If you do not follow these precautions you or others
could be killed or seriously injured.
2-3-5-3
Machines without Float Option.
1 Make sure the area beneath the load is clear.
2 Open the engine compartment top cover. (see Engine A

Compartment Access.)
3 Move lever A slowly in the direction shown to lower

the load. 378420
4 As soon as the load is lowered, close the valve by

returning the lever A to its previous position.
5 Close and lock the engine compartment top cover.

B
Machines with Float Option
1 Make sure the area beneath the load is clear.
2 Remove the floor plate.
3 Push in knob B slowly to lower the load.
4 Replace the floor plate.
334110
4320-2

58
OPERATION 58
TESTING THE PARKING BRAKE
! WARNING
Before testing the parking brake make sure the area
around the machine is clear of people.
A
2-2-4-5
Test the brake on a level, dry surface.
Make sure your seat belt is securely fastened.
! WARNING
Do not drive the machine without wearing the seat
belt, properly fastened and adjusted.
2-2-3-9
378290
1 Raise the Attachment
The attachment should already be in the travelling

position as shown at A.
2 Make Sure the Parking Brake is Engaged P

The parking brake is engaged when the parking
brake switch B is illuminated. B
3 Test the Brakes
a Make sure that there are no obstructions or

people in front of or behind the machine, then
slowly operate the Drive Control to forward or
reverse. The machine should not move.
b If the machine has not moved, gradually 378660
increase the engine speed to its preset
maximum. The machine should not move.
c Reduce the engine speed to idle and set the
Drive Control to neutral.
Note: If the machine moved during the test, have your

JCB distributor inspect the brake. Do not use the machine
with faulty brakes.
! WARNING
Do not use a machine with a faulty parking brake.
3-2-3-10
! CAUTION
Non approved modifications to drive ratios, machine
weight or wheel and tyre sizes may adversely affect
the performance of the parking brake.
3-2-3-11/1
4320-1


61
MAINTENANCE 61
SERVICE REQUIREMENTS
Introduction Owner/Operator Support

Your machine has been designed and built to give JCB together with your Distributor wants you to be
maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do
wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your
machine was inspected both at the Factory and by your Distributor's Service Department which is there to help
Distributor to ensure that it reaches you in optimum you!
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as You will have been given the names of the relevant service
specified in this Handbook, are carried out by an contacts at your Distributor when the machine was
approved JCB Distributor at the recommended intervals. installed.
To get the most from your Distributor please help the staff
Maintenance to satisfy you by:
This section of the Handbook gives full details of the 1 Giving your name, address and telephone number.
service requirements necessary to maintain your JCB
machine at peak efficiency. 2 Quoting your machine model and serial number.
To further protect your machine's performance it is 3 Date of purchase and hours of work.
essential your JCB Distributor carries out an initial service
and inspection when the machine is one month old or 4 Nature of the problem.
when it has completed 250 hours of operation (whichever
occurs first). You should notify your Distributor in advance Remember, only your JCB Distributor has access to the
to allow the necessary arrangements to be made. vast resources available at JCB to help support you. In
addition, your Distributor is able to offer a variety of
It can be seen from the Service Schedules on the programmes covering Warranty, Fixed Price Servicing,
following pages that many essential service checks should Safety Inspections, including weight tests, covering both
only be carried out by a JCB trained specialist. Only JCB legal and insurance requirements:
Distributor Service Engineers have been trained by JCB to
carry out such specialist tasks, and only JCB Distributor
Service Engineers are equipped with the necessary Service/Maintenance Agreements
special tools and test equipment to perform such tasks,
thoroughly, safely, accurately and efficiently. To help plan and spread the costs of maintaining your
machine, we strongly recommend you take advantage of
JCB regularly updates its Distributors advising them of any the many Service and Maintenance Agreements your
product developments, changes in specifications and Distributor can offer. These can be tailor made to meet
procedures. Therefore only a JCB Distributor is fully able your operating conditions, work schedule etc.
to maintain and service your machine.
Please consult your JCB Distributor for details.
Remember, if your machine has been correctly
maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.
4320-1

62
MAINTENANCE 62
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand this information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used properly 3 Note the following when removing engine oil from
for their intended purposes. skin:
However, excessive or prolonged skin contact can remove a Wash your skin thoroughly with soap and water.
the natural fats from your skin, causing dryness and
irritation. b Using a nail brush will help.
Low viscosity oils are more likely to do this, so take c Use special hand cleansers to help clean dirty
special care when handling used oils, which might be hands.
diluted with fuel contamination.
d Never use petrol, diesel fuel, or paraffin for
Whenever you are handling oil products you should washing.
maintain good standards of care and personal and plant
hygiene. For details of these precautions we advise you to e Avoid skin contact with oil soaked clothing.
read the relevant publications issued by your local health
authority, plus the following. f Don't keep oily rags in pockets.
Storage g Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children. h Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers. First Aid - Oil
Waste Disposal Eyes

In the case of eye contact, flush with water for 15 minutes.
All waste products should be disposed of in accordance If irritation persists, get medical attention.
with all the relevant regulations.
Swallowing
The collection and disposal of used engine oil should be in If oil is swallowed do not induce vomiting. Get medical
accordance with any local regulations. Never pour used advice.
engine oil into sewers, drains or on the ground.
Skin
In the case of excessive skin contact, wash with soap and
Handling water.
New Oil
Spillage
There are no special precautions needed for the handling
or use of new oil, beside the normal care and hygiene Absorb on sand or a locally approved brand of absorbent
practices. granules. Scrape up and remove to a chemical disposal
area.
Used Oil
Fires
Used engine crankcase lubricants contain harmful
contaminants. Extinguish with carbon dioxide, dry chemical or foam.
Fire-fighters should use self-contained breathing
Here are precautions to protect your health when handling apparatus.
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact

with used engine oils.
2 Apply a barrier cream to the skin before handling used

engine oil.
4320-1

63
www.WorkshopManuals.co.uk 63
MAINTENANCE
SERVICE SCHEDULES
A badly maintained machine is a danger to the operator ! WARNING

and the people working around him. Make sure that the
Maintenance must be done by suitably qualified
regular maintenance and lubrication jobs listed in the
personnel. Before attempting any maintenance work,
service schedules are done to keep the machine in a safe
make sure the machine is safe. Park on level ground. If
and efficient working condition.
it is necessary to work with the loader arm raised, then
the loader arm safety strut must be fitted, as shown in
Apart from the daily jobs, the schedules are based on
Loader Arm Safety Strut in MAINTENANCE section.
machine running hours. Keep a regular check on the 2-3-1-1
hourmeter readings. Do not use a machine which is due
for a service. Make sure any defects found during the
regular maintenance checks are rectified immediately.
Every 10 Operating Hours or Daily Every 50 Operating Hours or Weekly

whichever occurs first whichever occurs first
Clean Do the Daily jobs plus:
1 Machine generally, including cab interior
2 Radiator matrix and oil cooler Check (Engine Stopped)
3 Quickhitch locking peg housings 1 Oil cooler connections
2 Radiator hoses and condition
Check (Engine Stopped) 3 Fuel filter and sedimenter (drain if necessary)
1 Generally for damage, including ROPS/FOPS 4 Alternator belt tension
structure 5 Hoses and pipework for chafing and damage
2 Engine cooling system for leaks 6 Track tension (tracked machine only)
3 Engine coolant level and antifreeze strength
4 Fuel system for leaks and contamination Grease
5 Hydraulic oil level 1 Loader arm pivot points
6 Hydraulic system for leaks 2 Lift ram pivots
7 Engine oil level and condition
8 Engine generally for leaks Every 100 Operating Hours or 2 Weekly
9 Tyre pressures and condition
10 Tightness of wheel nuts
whichever occurs first
11 Windscreen washer level (if fitted) Do the Daily and 50 hour jobs plus:
12 Seat belt condition and security
13 Operation of horn Clean
14 Operation of roadlights and beacon (if fitted) 1 Battery terminals
2 Hydraulic tank breather
Check (Engine Running)
1 Warning lights extinguished Check (Engine Stopped)
2 Exhaust for excessive smoke 1 Ram piston rods for damage and corrosion
3 Operation of parking brake 2 Air cleaner hose security
4 Operation of reverse alarm (if fitted) 3 Wiring for chafing
Grease Oil
1 Quickhitch pivot pins 1 All linkage points
2 Restraint pivots
3 Throttle controls and linkages
4 All hinges
5 Manual control shafts
4320-1

64
MAINTENANCE 64
SERVICE SCHEDULES
(continued)
Every 250 Operating Hours or Monthly Every 1000 Operating Hours or Yearly
whichever occurs first whichever occurs first
Do the Daily to 100 hour jobs plus: Do the Daily to 500 hour jobs plus:
Clean Check (Engine Stopped)

1 Air cleaner dust valve 1 Drive chain tension*
2 Valve clearances*
Check (Engine Stopped)
1 Pivot pins and bushes Check (Engine Running)
1 Idling speed*
Check (Engine Running) 2 Max. no load speed*
1 Exhaust system security/fouling 3 Pulled down speed*
2 Exhaust for excessive smoke 4 M.R.V. pressure*
3 Cooling system for leaks 5 Transmission pressure*
4 Throttle system and control cable
5 Operation of all hydraulic services Change
6 Operation of control isolation (inc. valve spool locks) 1 Air filter inner element
7 Operation of electrical system 2 Drive chain case oil
8 Operation of attachments 3 Hydraulic tank breather* (see note 4)
9 Operation of transmission 4 Track roller oil and seals* (tracked machine only)
5 Track idler wheel oil and seals* (tracked machine only)
Change
1 Fuel filter element
Every 2000 Operating Hours or 2 Yearly
whichever occurs first
Every 500 Operating Hours or 6 Monthly
whichever occurs first Do the Daily to 1000 hour jobs plus:
Do the Daily to 250 hour jobs plus: Change

1 Hydraulic fluid*
Check (Engine Stopped) 2 Suction strainer*
1 Drive chain case oil level 3 Engine coolant
2 Battery charge and condition 4 Chain case breather*
3 Battery electrolyte (if applicable)
4 Engine and pump mounting bolts for tightness*
5 Tightness of wheel hub bolts to chassis* Note 1: We recommend that service procedures marked
6 Hydraulic motor mounting bolts* by an * be carried out by a recognised JCB distributor.
Change Note 2: Engine oil should be changed every 250 hours if

1 Engine oil and filter (see Note 2) machine is working in arduous applications.
2 Air filter outer element (see Note 3)
3 Hydraulic fluid filter Note 3: Air Cleaner Outer Element should be changed
4 High-flow hydraulic filter every 100 hours if machine is working in dusty conditions.
Note 4: Hydraulic Tank Breather should be changed more

frequently if machine is working in dusty conditions.
4320-1

65
MAINTENANCE 65
CLEANING THE CAB FLOOR AND REAR CHASSIS
Special provision is made for cleaning out the cab and rear
chassis.
To clean the cab proceed as follows:
1 Stop the engine and remove the starter key.
2 Remove blanking plate A to allow water to escape.
3 Hose out the machine floor taking care not to get water
into the electrical circuits.
Note: Hose pressure should not be too high.
4 Take whatever steps are necessary to get rid of any dirt A

and debris. Get rid of as much water as possible by
giving the chassis time to drain and by drying out with
cloths.
378650
5 Once the chassis is dry, re-secure the blanking plate.
To clean the rear chassis proceed as follows:
1 Raise the front of the machine by lowering the

Quickhitch frame onto wooden blocks. This is to help C
water to drain from the rear chassis.
2 Stop the engine and remove the starter key.
3 Slacken securing bolts and rotate blanking covers B

to uncover drain holes. Unscrew five securing bolts
B B
and remove rear cover C.
4 Remove accumulated dirt and debris from inside the 385340

rear chassis area using a water hose if necessary.
5 Replace rear cover C and secure blanking covers B.
ROPS/FOPS CAB/CANOPY
Checking the ROPS/FOPS Cab/Canopy
! WARNING
The machine is fitted with a Roll Over Protection 1 Check the cab/canopy for damage.
Structure (ROPS) and a Falling Objects Protection
Structure (FOPS). You could be killed or seriously 2 If damage is found,consult your JCB distributor. It
injured if you operate the machine with a damaged or may be necessary to obtain a complete new
missing ROPS/FOPS. If the ROPS/FOPS has been in an cab/canopy.
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
4320-2

66
MAINTENANCE 66
LOADER ARM SAFETY STRUT
Installing the Safety Strut Removing the Safety Strut
! WARNING ! WARNING
Raised loader arms can drop suddenly and cause You could be killed or injured if the loader control is
serious injury. Before working under raised loader accidentally operated. Make sure no-one comes near
arms, fit the loader arm safety strut. the machine while you remove the safety strut.
2-1-1-6 2-3-1-3
! WARNING
1 Make sure that the drive control is in the neutral (rest)
You could be killed or seriously injured if the loader
position.
control is accidentally operated. Make sure that no-
one goes near the machine whilst you fit the safety
2 Raise the loader arm to take the weight off the safety
strut.
16-3-1-5 strut A. Stop the engine.
1 Empty the shovel or attachment, if appropriate, and 3 Remove the strut:

raise the loader arm enough to fit the safety strut.
a Release securing strap B.
2 Stop the engine. b Remove the safety strut from the lift ram.
c Return the safety strut to its stowage position C
3 Fit the strut: on top of the lift arm.
a Remove the strut from its stowage position C on

top of the lift arm.
b Place the strut around the lift ram.
c Secure the strut A into position using strap B.
4 Start the engine.
5 Slowly lower the loader arm onto the safety strut. Stop
the movement immediately the weight of the arm is
supported by the strut.
Note: Extreme care must be taken when lowering the

loader arm onto the safety strut. 'Feather' the lever to
lower the loader arm slowly.
C
B
378500
4320-1

67
MAINTENANCE 67
ENGINE COMPARTMENT ACCESS
Access to the engine compartment is provided by a Radiator and Oil Cooler

hinged top cover and a removable rear panel.
1 Lowering the Radiator and Oil Cooler
! CAUTION
The engine has exposed rotating parts. Do not open a Stop the engine.
the engine cover while the engine is running. Do not b Open the top cover (see Top Cover, Step 1
use the machine with the cover open. above) and rear panel (see Rear Panel, Step 1
INT-2-1-6/1 above).
b Unscrew securing nuts C and swing the radiator
Top Cover and oil cooler assembly down.
2 Raising the Radiator and Oil Cooler

1 Opening
a Swing the radiator and oil cooler assembly up and
a Stop the engine.
secure with nuts C.
b Unlock handle A with the key provided and turn
the handle to release the top cover.
c Raise the top cover which is supported by a gas
strut.
A
2 Closing
a Lower the top cover.

b Turn handle A to secure the top cover. Lock C
handle A and remove the key.
Rear Panel
1 Lowering the Panel
a Stop the engine.

b Open the top cover (see Top Cover, Step 1
above).
b Unscrew T handles B and lower the rear panel. B
The panel may be removed from the machine if
required.
B
2 Raising the Panel
a Swing the panel up and secure with T handles B. 378551
CLEANING THE RADIATOR AND OIL COOLER
1 Park the machine on level ground within reach of a 4 Use a brush to remove any further debris.
compressed air line or water supply. Stop the engine
and allow to cool. 5 Inspect the radiator and oil cooler for damage.
2 Open the rear panel and lower the radiator and oil 6 Swing the radiator and oil cooler assembly upwards
cooler assembly (see Engine Compartment Access and secure. Close the rear panel.
above).
3 Use compressed air or water to remove debris from

the radiator and oil cooler taking care not to damage
the radiator fins. If water is used ensure that the
pressure is not too high.
4320-3

68 MAINTENANCE 68
SEAT BELT
Checking Seat Belt Condition and

Security
! WARNING When checking the seat belt, look for signs of fraying and
stretching. Make sure the stitching is not loose or
A JCB approved seat belt is fitted to your machine.
damaged. Make sure the buckle assembly is working
Replace it with a new one if it is damaged, if the fabric
correctly and not damaged. Fit a new seat belt every three
is worn, or if the machine has been in an accident. Fit a
years.
new seat belt every three years regardless of
condition.
2-3-1-8/1 Make sure the belt mounting bolts are undamaged,
correctly fitted and tightened.
GREASING (10 HOURS)
The machine must be greased regularly to keep it working Quickhitch Pivot Pins
efficiently. Regular greasing will also increase the
machine's working life. Lower the loader arm as far as it will go. Tilt the Quickhitch
fully forward to facilitate access to the grease points.
Grease should be applied with a grease gun, normally two Switch off the engine and ensure it cannot be started
strokes of the gun should be sufficient. Stop the greasing while you are doing this job.
procedure when fresh grease appears at the joint. Use the
recommended grease. (See Fluids, Capacities and Total of 4 grease points.
Lubricants.)
In the following illustrations, the grease points are

numbered. Count off the grease points as you apply
grease to each one. Refit the dust caps after greasing.
4
3
2
378400
4320-1

69
MAINTENANCE 69
GREASING (50 HOURS)
! WARNING
Raised loader arms can drop suddenly and cause
serious injury. Before working under raised loader
arms, fit the loader arm safety strut.
2-1-1-6
Loader Arm Pivot Point Lift Ram Pivots
Switch off the engine and ensure it cannot be started Total of 2 grease points B
while you are doing this job.
Total of 2 grease points A (one each end of pin)
B
378390
4320-1

70
MAINTENANCE 70
GREASING AND OILING (100 HOURS)
Safety Restraint mechanism

Switch off the engine and ensure it cannot be started
1 Oil the moving parts of the safety restraint

mechanism.
Control Linkage (manual machines) A

1 Remove the seat and seat base.

B A
2 Oil the moving parts of the manual controls at A.
3 Apply grease at nipples B. A A

A A
A
A A
B
C
382170
Throttle Pedal (if fitted)

378460
Oil the moving parts of the throttle pedal C.
4320-1

71
MAINTENANCE 71
ENGINE AIR FILTER
Changing the Elements

Note: In a dusty working environment, the outer element 1 Stop the engine.
may have to be renewed more frequently than the service
schedule recommendation. A new inner element must be 2 Open the engine compartment top cover.
fitted at least every third time the outer element is changed.
3 Release clips A and remove cover B.
As a reminder, mark the inner element with a felt tipped
pen each time the outer element is changed. Do not
4 Remove outer element C. Take care not to tap or
attempt to wash or clean the elements - they must only be
knock the element. If necessary, remove inner
renewed.
element D.
! CAUTION
5 Clean inside the canister E, cover B and dust valve F.
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates. 6 Carefully insert the new elements into the canister.
2-3-3-1
Ensure they are pushed fully into their spigots. Fit
! CAUTION cover B with dust valve F at the bottom.
Do not run the engine when the outer element has 7 Make sure that the wire is connected to the Air Filter
been removed. Blocked switch.
16-3-3-1
Note: Do not run the engine with the dust valve F removed.
C
D
F
378130
4320-1

72
MAINTENANCE 72
ENGINE OIL AND FILTER
Checking the Oil Level

! WARNING
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2
1 Park the machine on level ground and lower the

attachments to the ground.
2 Stop the engine and remove the starter key. A

3 Open the engine compartment top cover (see Engine
Compartment Access).
B
4 Check that the oil level is within the marked area on
the dipstick A.
5 If necessary, add the recommended oil through the 383020

filler point B. (See Fluids, Capacities and
Lubricants.)
6 Make sure the filler cap and the dipstick are secure.
Changing the Oil and Filter

Refer to Lubricants - Health and Safety before
proceeding.
D
Drain the oil when the engine is warm as contaminants
held in suspension will then be drained with the oil.
! WARNING
Make the machine safe before getting beneath it. Park
the machine on level ground and lower the
attachments. Stop the engine and remove the starter
key. Make sure the parking brake is engaged.
Disconnect the battery to prevent the engine being
started. Chock all four wheels before getting under the
machine.
3-3-1-1 C
! WARNING
Hot oil and engine components can burn you. Make B
sure the engine is cool before doing this job. 378410
2-3-3-2
1 Do Steps 1 to 2 of Checking the Oil Level. Note: There are three drain plugs located behind the
access plate. The engine oil drain is the one which is NOT
2 Open the engine compartment top cover (see Engine coloured (zinc plated).
Compartment Access).
3 Unscrew five bolts B and remove the access plate C

at the back of the machine to expose the drain plug.
4320-1

73
MAINTENANCE 73
ENGINE OIL AND FILTER

(continued)
Changing the Oil and Filter (cont’d)

4 Place a suitable container beneath the machine to
catch the oil.
! WARNING
Oil will gush from the hole when the drain plug is
removed. Hot oil and engine components can burn
you. Keep to one side when you remove the plug.
13-3-1-15
5 Taking care to select the correct drain plug D, remove

the plug to allow oil to flow into the container.
6 After emptying the sump, replace the drain plug D and

refit the access plate C.
7 Unscrew the filter canister E, using a chain wrench if

necessary. Remember that it will contain some oil.
8 Clean filter head F.
9 Add clean engine oil to the new filter canister. Allow

time for the oil to pass through the filter element.
10 Smear the seal G on the new filter canister E with

clean engine oil.
11 Screw in the new filter canister - hand tight only.
12 Fill the engine with the recommended oil, to the MAX

mark on the dipstick A, through the filler point B (see F
Fluids, Capacities and Lubricants). Wipe off any
spilt oil, refit the filler cap and make sure it is secure.
13 Make sure the engine will not start by removing the E

engine shut-off solenoid (ESOS) fuse (see Fuses). G
Turn the engine using the starter key until the oil
pressure warning light is extinguished.
14 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has cooled,
check the oil level and, if necessary, top up with clean 390170
engine oil.
Note: Old engine oil and filters should be disposed of in

accordance with local Health and Safety regulations.
4320-2

74
MAINTENANCE 74
ENGINE COOLING SYSTEM
Coolant Mixtures Checking the Coolant Level

The protection provided by JCB Four Seasons Anti-freeze ! WARNING
and Summer Coolant is shown below. If any other anti-
The cooling system is pressurised when the coolant is
freeze is used, refer to the manufacturer’s instructions and
hot. Hot coolant will burn you. Make sure the engine is
ensure that a corrosion inhibitor is included.
cool before checking the coolant level or draining the
system.
DO NOT use solutions of more than 50% or damage to 2-3-3-3
the engine may occur.
1 Park the machine on level ground. Stop the engine
Solution Maintains circulation Protects against and let it cool down. Open the engine compartment
down to damage down to top cover.
deg C deg F deg C deg F
50% -33 -27 -45 -49 2 Check the level of coolant in the expansion bottle A. If
necessary remove the filler cap and top up to the level
The strength of the anti-freeze solution must be checked indicated.
at least once a year, preferably at the beginning of the
cold period. 3 Refit the filler cap and make sure it is tight.
It is an advantage to leave the anti-freeze in all the year 4 Run the engine for a while to raise the coolant to
round as it gives continued protection against corrosion. working temperature and pressure. Stop the engine
Always renew the anti-freeze every two years. and check for leaks.
A 50% anti-freeze mixture must be used even if frost 5 Close and lock the engine compartment top cover.
protection is not needed. This gives protection against
corrosion and raises the coolant’s boiling point.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling neat or diluted antifreeze.
7-3-4-4
378140
4320-1

75
MAINTENANCE 75
ENGINE COOLING SYSTEM

(continued)
Changing the Coolant Cleaning the Coolant Radiator and Oil

Cooler
1 Park the machine on level ground. Stop the engine
and let it cool down. Open the engine compartment 1 Park the machine on level ground within reach of a
top cover (see Engine Compartment Access). water supply. Stop the engine and remove the starter
key. Open the engine compartment top cover and
2 Carefully loosen radiator filler cap B just enough to let remove the rear panel (see Engine Compartment
any pressure escape. Remove the cap when all Access).
pressure is released.
2 After allowing the engine to cool down use gentle
3 Unscrew five bolts C and remove the access plate D water pressure to remove debris from the radiator,
at the back of the machine. directing the hose from the outside of the radiator.
Water will drain through the aperture at the base of
Note: There are three drain plugs located behind the the radiator cowl. DO NOT use high water pressure
access plate. The engine coolant drain is the one which is otherwise the radiator core may be damaged.
coloured BLUE.
3 Direct the hose to remove debris from the hydraulic oil
4 Taking care to select the correct drain plug E, remove cooler, taking care not to damage the core. Keep
the plug and allow the coolant to drain. water away from the reverse alarm unit, if fitted.
5 Flush the system by pouring clean water into radiator 4 Inspect the radiator and oil cooler for damage.
filler cap B.
5 Refit the engine compartment rear panel and close
6 Clean and refit drain plug E. and lock the top cover.
7 Fill the system through filler cap B, using the

necessary anti-freeze solution, up to the neck of the
filler. (See Coolant Mixtures.) Refit the filler cap B.
8 Fill the expansion bottle A, using the necessary anti- E

freeze solution, to the level indicated.
9 Check for leaks.
10 Run the engine for a while to raise the coolant to

working temperature and pressure. Stop the engine
and check for leaks. Check the level in the expansion
bottle and top up if necessary.
11 Refit the access plate D.

D
C
378410
4320-1

76
MAINTENANCE 76
ENGINE ALTERNATOR BELT
Checking the Alternator Belt Tension

1 Park the machine on level ground.
2 Stop the engine.
3 Open the engine compartment top cover. A

4 When correctly set the belt has 10 mm (3/8 in)
deflection at point X.
C
5 If the belt requires adjusting proceed as below
Adjusting the Alternator Belt.
! WARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
D
Adjusting the Alternator Belt
B
1 Loosen bolts A, B, C and D securing the alternator.
2 Reposition the alternator until belt deflection at point

X is 10 mm (3/8 in).
X 192470
! CAUTION
Any leverage required to position the alternator must
be applied at the drive end bracket only, using a
wooden lever.
8-3-2-1
3 Tighten bolts A, B, C and D, ensuring that bolt A is the

last to be tightened.
4320-1

77
MAINTENANCE 77
DRIVE CHAIN LUBRICATION
The final drive to the wheels is by chains. A chain casing Changing the Oil
on each side of the machine houses two chains, one to
the front wheel and one to the rear wheel. The chains run 1 Park the machine on level ground.
in an oil bath.
2 Stop the engine.
3 On the right side of the machine, unscrew the eight
1 Park the machine on level ground. retaining bolts and remove cover A with its gasket.
2 Stop the engine. 4 Place a suitable receptacle under drain plug B to

collect the oil.
3 On the right side of the machine, unscrew the eight
retaining bolts and remove cover A with its gasket. 5 Remove plug B with its washer and completely drain
Check that the oil level is up to the bottom of the the chain casing.
aperture.
6 Clean plug B, its washer and its hole. Renew the
4 If necessary, top up using the recommended oil. (See sealing washer if necessary.
Fluids, Capacities and Lubricants.) Wipe up any oil
spillage. 7 Refit plug B.
5 Using a new gasket, refit cover A and tighten the eight 8 Using the recommended oil (see Fluids, Capacities
retaining bolts. and Lubricants), fill the chain casing via the cover A
aperture until the oil is level with the bottom of the
6 Repeat steps 3 to 5 on the left side of machine. aperture. Wipe up any oil spillage.
9 Using a new gasket, refit cover A and tighten the eight

retaining bolts.
10 Repeat steps 3 to 9 on the left side of machine.
B
378250
4320-1

78
MAINTENANCE 78
FUEL SYSTEM
Types of Fuel Petrol

! WARNING
Use good quality diesel fuel to get the correct power and Do not use petrol in this engine. Do not mix petrol with
performance from your engine. The recommended fuel the diesel fuel. In storage tanks the petrol could rise to
specification for JCB engines is given below. the top and form flammable vapours.
INT-3-1-6
Cetane Number: 45 (minimum)
Viscosity: 2.5/4.5 Centistokes at 40°C (104°F) Advice
Density: 0.835/0.855 kg/litre
(0.872/0.904 lb/pint) If you have to use non-standard fuels, contact your JCB
Sulphur: 0.5% of mass (maximum) distributor for advice on engine adjustments and oil
Distillation: 85% at 350 °C (662 °F) change periods.
Cetane Number Fatty Acid Methyl Ester Fuels as a

Indicates ignition performance. Fuel with a low cetane replacement for Diesel Fuels
number can cause cold start problems and affect
combustion. Fuel resources such as Rape Methyl Ester and Soybean
Methyl Ester, collectively known as Fatty Acid Methyl
Viscosity Esters, are being used as alternatives and extenders for
Is the resistance to flow. If this is outside limits, the engine mineral oil.
performance can be affected.
Fatty Acid Methyl Esters must conform to certain
Density standards to be of acceptable quality, just as mineral oils
Lower density will reduce engine power. Higher density do at present.
will increase both engine power and exhaust smoke.
Consult your JCB distributor for advice about the use of
Sulphur Fatty Acid Methyl Ester fuels as improper application may
High sulphur content can cause engine wear. (High impair engine performance.
sulphur fuel is not normally found in North America,
Europe or Australia.) If you have to use high sulphur fuel Filling the Tank
you must also use a highly alkaline engine lubricating oil;
or change the normal oil more frequently. ! WARNING
Diesel fuel is flammable; keep naked flames away from
Low sulphur fuels are commonly used throughout the the machine. Do not smoke while refuelling the
world. These fuels contain fewer lubrication additives. The machine or working on the engine. Do not refuel with
fuel injection pump is lubricated by the fuel; therefore the engine running. There could be a fire and injury if
using low sulphur fuel may, in the long term, affect the you do not follow these precautions.
pump. If you have to use low sulphur fuel you are advised INT-3-2-2
to use a lubrication additive as recommended by your fuel
supplier. At the end of every working day, fill the tank with the
correct type of fuel. This will prevent condensation from
Distillation developing in the fuel tank overnight.
This indicates the mixture of different hydrocarbons in the
fuel. A high ratio of lightweight hydrocarbons can affect A gauge in the cab indicates how much fuel is in the tank.
the combustion characteristics.
We recommend that, if possible, you lock the fuel cap A to
Fuel Standards prevent theft and tampering.
Consult your fuel supplier or JCB distributor about the

suitability of any fuel you are unsure of.
Low Temperature Fuels

Special winter fuels may be available for engine operation
at temperatures below 0 °C (32 °F). These fuels have a A
lower viscosity. They also limit wax formation in the fuel at
low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter).
Flow improvers may also be available. These can be

added to the fuel to reduce wax formation.
378160
4320-1

79
MAINTENANCE 79
FUEL SYSTEM
(continued)
Draining the Fuel Sediment Bowl

The sediment bowl is located on the left hand side of the
engine compartment.
1 Stop the engine.
2 Open the engine compartment top cover.
3 Slacken drain plate bolts D and rotate drain plate E,

located under the machine, to uncover the drain hole.
4 Look in bowl A. If it contains sediment, do steps 5 to

8. If there is water but no sediment, drain off the water
by opening tap B. Make sure tap B is turned off and
secure.
5 Support bowl A; unscrew nut C. Remove the bowl.

C
6 Wash the bowl. Use clean fuel.
7 Refit the bowl, make sure the gasket is seated

correctly.
A
8 Bleed the system. B 378700
! CAUTION
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11
9 Reposition drain plate E and tighten bolts D. Close

E
and lock the engine compartment top cover.
D D
382931
4320-2

80
MAINTENANCE 80
FUEL SYSTEM
(continued)
Changing the Fuel Filter Element

The fuel filter is located on the right hand side of the B
engine.
1 Stop the engine.
3 Unscrew the filter element A. The element is hand

tight but may require a strap wrench to remove. The
filter will be full of fuel.
4 To assist with bleeding, fill the new filter element with

fuel before fitting. Install new element A hand tight
only. Check for leaks.
5 Bleed the fuel system as described on the following

page.
! CAUTION
damage the fuel injection pump. After maintenance, A
the system must be bled to remove any air.
2-3-3-11
S218870
Bleeding the Fuel System
If either the sediment bowl or main filter has been
disturbed it will be necessary to bleed air from the system.
! CAUTION
damage the fuel injection pump. After maintenance,
remove air from the system as detailed below.
2-3-3-7
1 Slacken bleed screw B and operate the priming pump

X by squeezing it until fuel spurts from the loosened
connection with no entrapped air.
2 Tighten the bleed screw and check the system for

leaks. Tighten connections or change seals as
required.
X
385330
4320-2

81
MAINTENANCE 81
HYDRAULIC SYSTEM
! WARNING
Fine jets of hydraulic oil at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
oil 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 X
hydraulic oil. If hydraulic oil penetrates your skin, get
medical help immediately.
INT-3-1-10/1

The oil level should be checked when the oil is cool or cold.
1 Lower the lift arm and fully crowd the shovel/

attachment as shown at X. Stop the engine.
2 Look at the oil level in the sight glass A. The level

should be at the mark on the sight glass.
3 If more oil is needed, open the engine compartment

top cover.
B
4 Top up the hydraulic tank through filler cap B with
engine oil. (See Fluids, Capacities and Lubricants.)
A
! CAUTION
If the oil is cloudy, water or air has entered the system.
This could damage the hydraulic pump. Contact your
JCB distributor.
7-3-6-1 378170
Changing the Filter

1 Stop the engine and wait until the system has cooled.
3 Loosen the hydraulic tank filler cap B and allow all

pressure to dissipate. Remove the filler cap.
4 Unscrew the old filter canister C, using a chain

wrench if necessary, and discard. C
5 Lubricate seal D on the new filter canister with clean
engine oil.
6 Screw on the new filter canister hand tight only.
7 Add engine oil through filler point B. (See Fluids, D

Capacities and Lubricants).
8 Refit cap B, run the engine for a few minutes, then re-
check the oil level.
378180
Note: Old filters should be disposed of in accordance with
local Health and Safety regulations.
4320-2

82
MAINTENANCE 82
HYDRAULIC SYSTEM
(continued)
Changing the High-flow Filter

1 Stop the engine and wait until the system has cooled.

F
3 Loosen the hydraulic tank filler cap B and allow all
pressure to dissipate. Remove the filler cap.
4 Remove the seat base and floor plate.
4 Unscrew the old filter canister E, using a chain wrench

if necessary, and discard.
E
5 Lubricate seal F on the new filter canister with clean
engine oil.
6 Screw on the new filter canister hand tight only. 378190
7 Add engine oil through filler point B. (See Fluids,

Capacities and Lubricants).
8 Refit cap B, run the engine for a few minutes, then re-
check the oil level.
9 Replace the floorplate and seat base.
Note: Old filters should be disposed of in accordance with

local Health and Safety regulations.
4320-1

83
MAINTENANCE 83
BATTERY
Safety
! WARNING ! WARNING
Batteries give off an explosive gas. Do not smoke Battery
when handling or working on the battery. Keep the A battery with frozen electrolyte can explode if it is
battery away from sparks and flames. used or charged. Do not use a machine with a frozen
battery. To help prevent the battery from freezing, keep
Battery electrolyte contains sulphuric acid. It can burn the battery fully charged.
you if it touches your skin or eyes. Wear goggles. INT-3-1-7
Handle the battery carefully to prevent spillage. Keep
metallic items (watches, rings, zips etc) away from the ! WARNING
battery terminals. Such items could short the terminals Electrolyte
and burn you. Battery electrolyte is toxic and corrosive. Do not
breathe the gasses given off by the battery. Keep the
Set all switches in the cab to OFF before electrolyte away from your clothes, skin, mouth and
disconnecting and connecting the battery. When eyes. Wear safety glasses. See Battery in
disconnecting the battery, take off the earth (-) lead MAINTENANCE section for First Aid Treatment.
first. INT-3-2-1/2
When reconnecting, fit the positive (+) lead first. ! WARNING

Battery Terminals
Re-charge the battery away from the machine, in a The machine is negatively earthed. Always connect the
well ventilated area. Switch the charging circuit off negative pole of the battery to earth.
before connecting or disconnecting the battery. When
you have installed the battery in the machine, wait five When connecting the battery, connect the earth (-) lead
minutes before connecting it up. last.
First Aid - Electrolyte When disconnecting the battery, disconnect the earth
(-) lead first.
INT-3-1-9
Do the following if electrolyte:
! CAUTION
GETS INTO YOUR EYES
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
Immediately flush with water for 15 minutes, always get
receptacle and must be disposed of in accordance
medical help.
with local environmental waste regulations.
INT-3-1-12
IS SWALLOWED
! WARNING
Do not induce vomiting. Drink large quantities of water or
Keep metal watch straps, and any metal fasteners on
milk. Then drink milk of magnesia, beaten egg or
your clothes, clear of the positive (+) battery terminal.
vegetable oil. Get medical help.
Such items can short between the terminal and nearby
metal work. If this happens you can get burned.
GETS ONTO YOUR SKIN 5-2-2-4
Flush with water, remove affected clothing. Cover burns ! WARNING

with a sterile dressing then get medical help.
5-3-4-3/1
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
! CAUTION INT-3-1-4
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
4320-1

84
MAINTENANCE 84
BATTERY
(continued)
Checking the Electrolyte Level Warning Symbols

Maintenance free batteries used in normal temperature The following warning symbols may be found on the
climate applications should not need topping up. battery
However, in certain conditions (such as prolonged
operation at tropical temperatures or if the alternator Symbol Meaning
overcharges) the electrolyte level should be checked as
described below.
Keep away from children.
The battery is mounted in the engine compartment.
A289230M
1 Stop the engine.
2 Open the engine compartment top cover. Shield eyes.
3 Remove the battery top cover A. A289260M
! WARNING
No smoking, no naked flames,
Do not top up the battery with acid. The electrolyte no sparks.
could boil out and burn you.
2-3-4-6 A289280M
4 Carefully remove battery cell cover(s) B. Make sure

the level in each cell is 6 mm (1/4 in) above the plates. Explosive gas.
If necessary, top up with distilled water. Refit battery
cell cover(s) B and refit the top cover A. A289250M

Battery acid.
A289240M
Note operating instructions.
A289270M
B B
378540 S174422
4320-1

85
MAINTENANCE 85
ELECTRICAL SYSTEM
Fuses
The electrical circuits are protected by fuses. The fuses
are located behind a cover on the right hand side of the
cab as shown in the illustration. B A
7.5
7.5
7.5
7.5
7.5
15
15
10
15
10
40
20
10
15
5
5
5
5
Note: Depending on the number of options specified,
some of the fuses may not be fitted.
Fuse
No. Circuits Protected Size
A1 Spool Lock, Restraint Switch,

Cut-off Solenoids 15 Amp
A2 Junction Box/accessory socket 10 Amp
A3 Ignition Circuits 5 Amp
A4 ESOS, Cold Start Advance 7.5 Amp
A5 Front Work Lights 20 Amp
A6 Rear Work Light 7.5 Amp
A7 2 Speed Motor Control 5 Amp
A8 Air Conditioning 40 Amp
A9 Front Horn 7.5 Amp
A10 Beacon, Interior Light 10 Amp
B1 Right Hand Side and Tail Lights 5 Amp 378530
B2 Left Hand Side and Tail Lights,

Number Plate Light 5 Amp
B3 Head Light Dip Beam 15 Amp
B4 Direction Indicators 7.5 Amp
B5 High Flow Hydraulics 5 Amp
B6 Heater Blower 10 Amp
B7 Wipers and Washers 15 Amp
B8 Brake Lights 7.5 Amp
B9 Self Level Circuit 5 Amp
B10 Hazard Warning 15 Amp
4320-1

86
MAINTENANCE 86
ELECTRICAL SYSTEM
(continued)
Primary Fuses Relays

To further protect the machine wiring harnesses and The relays are located under fuse cover B on the right
electrical circuits, a primary fuse box is fitted to the battery hand side of the cab as shown in the illustration.
positive terminal as shown at A. Remember to check the
main fuses as well as the primary fuses shown below. 5 Parking Brake
6 Horn
1 Ignition relay 60 Amp 7 Neutral Start
2 Beacon, horn, road lights, indicators 40 Amp 8 Ignition
3 Starter switch, all ignition switched circuits 70 Amp 9 2 Speed
4 Air Conditioning 60 Amp
Note: Relay 5 is located behind relay 6.
4 3
A 60A 70A
7.5
7.5
7.5
7.5
7.5
15
15
10
15
10
40
20
10
15
5
5
5
5
9 8 7 6
40A 60A
2 1 5
B
382300
378530
Light Bulbs
Work lights 55W Interior light 10W
Beacon 55W Indicators 21W
Side lights 5W Brake lights 21W
Headlights Warning lights 1.2W
Halogen type 55W
4320-1

87
MAINTENANCE 87
WINDSCREEN WASHER (OPTIONAL)
Fill the windscreen washer bottle A with a suitable liquid.

The liquid should contain a de-icing fluid to prevent it
freezing. Do not use engine coolant antifreeze.
332790
TRACKS
Track Adjustment
Correct track tension is important for good performance
and to prevent the tracks from dismounting. The track
tension is controlled by the forward idler which is attached
to a grease filled hydraulic cylinder. The track tension B
should be checked as follows:
1 Position machine on a smooth flat surface.
2 Thoroughly clean the track, making sure that all debris

is removed from around the sprocket and rollers.
Drive the machine backwards and forwards whilst
cleaning.
3 Drive the machine forwards to ensure that the slack is

at the top of the track.
4 Using a suitable straight edge, measure the sag at

F
position B which should be 5 to 10 mm (0.2 to 0.4 in).
E
5 If adjustment is required, unscrew bolts C and remove
access plate D. D
6 To tighten the track, pump grease into nipple E using
a grease gun. To loosen the track, carefully unscrew
hexagon plug F and allow the grease to flow into a C
suitable container. 378280
7 When correct adjustment is achieved, replace the

cover plate.
8 Repeat for opposite track.
4320-1

88
MAINTENANCE 88
TYRES AND WHEELS
Inflating the Tyres Checking the Wheel Nut Torques
! WARNING On new machines, and whenever a wheel has been

removed, check the wheel nut torques every two hours
Over-inflated or overheated tyres can explode. Do not
until they stay correct.
cut or weld the rims. Get a tyre/wheel specialist to do
any repair work.
5-3-2-4 Every day, before starting work, check that the wheel nuts
are tight.
These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure, call The correct torques are shown in the table below.
in a qualified tyre mechanic. The tyre mechanic should use
a tyre inflation cage and the correct equipment to do the
job. Front and Rear
1 Prepare the Wheel Nm lbf ft kgf m

244 180 25
Before you add air to the tyre, make sure it is correctly
fitted on the machine or installed in a tyre inflation
cage. ! WARNING
If, for whatever reason, a wheel stud is renewed, all the
2 Prepare the Equipment studs for that wheel must be changed as a set, since
the remaining studs may have been damaged.
Use only an air supply system which includes a 2-3-2-8
pressure regulator. Set the regulator no higher than
1.38 bar (20 lbf/in 2) above the recommended tyre
pressure. (See Tyre Pressures in SPECIFICATION
section for recommended tyres and pressures for your
machine).
Use an air hose fitted with a self-locking air chuck and

remote shut-off valve.
3 Add the Air
Make sure that the air hose is correctly connected to

the tyre valve. Clear other people from the area. Stand
behind the tread of the tyre while adding the air.
Inflate the tyre to the recommended pressure. Do not

over-inflate.
Renewing Segments of Optional

Non-Inflatable Tyres
Non-inflatable tyres are available as an option. These tyres
consist of a number of individual segments bolted to the
wheel rim.
A
Damaged segments can be renewed individually. Loosen
and remove the four nuts and washers A (two each side of
the wheel). Lift the segment clear by extracting its fixing
studs from the holes in the wheel rim.
S174460
Fit a new segment in reverse order to removal, then

tighten the retaining nuts to a torque of 28 Nm (21 lbf ft, 3
kgf m).
4320-1

89
MAINTENANCE 89
FLUIDS, CAPACITIES AND LUBRICANTS
ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION
Engine Oil 10.8 litres (2.4 UK gal) JCB High Performance 15W/40 ACEA E2:B2:A2, API CF-4/SG
-10 °C to 50 °C (14 °F to 122 °F)
JCB High Performance 10W/30 API CF-4/SG

-15 °C to 40 °C (5 °F to 104 °F)
Hydraulic 35 litres (7.7 UK gal) JCB High Performance 10W/30 API CF-4/SG
System JCB High Performance 15W/40 ACEA E2:B2:A2, API CF-4/SG
(top up only)
Cooling System JCB Four Seasons Antifreeze ASTM D3306, BS6580

Total Coolant 15 litres (3.3 UK gal) & Summer Coolant/Water
Antifreeze 7.5 litres (1.7 UK gal) (see Coolant Mixtures)
Fuel System 107 litres (23.5 UK gal) Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Grease Points — JCB HP Grease Lithium complex NLGI No. 2 consistency

including extreme pressure additives.
or JCB Special MPL-EP Grease Lithium based NLGI No. 2 consistency
including extreme pressure additives.
Chain Case - LH 10.8 litres (2.4 UK gal) Engine Oil

Chain Case - RH 12.5 litres (2.8 UK gal)
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without a load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100
hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
OBTAINING REPLACEMENT PARTS
We recommend you fit only JCB Genuine Parts. ! WARNING

Some parts of your machine have Warning Decals
Your distributor will need to know the exact model, build attached. Before you fit a replacement part, make sure
and serial number of your machine. The machine's serial it has its warning decal, fixed in its correct position.
number is stamped on a data plate which is mounted on (See Safety Decals in INTRODUCTION section). Contact
the left hand side of the rear turret. (See Identifying Your your distributor if the decal is missing.
Machine in INTRODUCTION section.) 2-3-5-2/1
The data plate also shows the serial numbers of the

engine and the hydraulic pump. Remember that if either of
these units have been changed, the serial number on the
data plate may be wrong. Check on the unit itself.
4320-2

90
MAINTENANCE 90
STORAGE
Storing the Machine

If the machine is not going to be used for an extended 6 Apply a light coating of suitable grease or petroleum
period of time, you must store it correctly to prevent jelly to all exposed ram piston rods.
deterioration.
7 Check all oil levels and replenish if necessary.
1 Thoroughly clean the machine to remove corrosive
products. 8 Check coolant level and condition. Replenish if
necessary.
2 Fill the fuel tank to prevent condensation forming in
the tank. 9 Remove and charge the battery. Store the battery in a
warm dry place and recharge periodically.
3 Park the machine on firm level ground (preferably
under cover). Make sure you do not park the machine 10 Check the tyre pressures. Adjust if necessary.
in an awkward position that would prevent it from
being towed at the end of the storage period (in case 11 Check the machine for worn or damaged parts.
the machine will not start). Replace if necessary.
4 Remove any attachments. Fully crowd the carriage 12 If possible, raise and securely support the machine on
and lower the arm to the ground. blocks to prevent distortion of the tyres. Otherwise
periodically rotate the road wheels.
5 Stop the engine.
4320-1

101
OPTIONAL ATTACHMENTS 101
INTRODUCTION
A wide range of optional attachments is available to Hand Held Attachments

increase the versatility of your machine. Only JCB
approved attachments can be used with your machine. Your machine may be fitted with auxiliary pipework to
Consult your JCB Distributor for the full list of approved allow the use of hand held attachments.
attachments available.
When using a hand held attachment, set the engine to
JCB attachments are designed and manufactured approximately half speed. If the charge pressure warning
specifically to suit the machine's hydraulic system, light illuminates, increase the engine speed slightly until
mounting arrangements and safe load requirements. the warning light goes out.
Attachments which are not designed for use with this
machine may cause damage and create safety hazards for
which JCB cannot be held responsible. In addition the
machine's warranty, “CE” and any other legislative
compliance may be affected by the use of non JCB
approved attachments.
2-4-1-13/2
! CAUTION
All hydraulically operated JCB attachments have built-
in relief valve protection. This may not be the case with
non-JCB attachments. Before installing a non-JCB
attachment on this machine ensure that it is equipped
with relief valve protection. If in doubt, contact your
JCB distributor.
3-4-1-2
Note: Auxiliary relief valves can be fitted to the machine's

loader valve block and set to the required pressure.
Contact your JCB distributor for more information.
Each attachment is supplied complete with instructions on

Safety, Installing and Removing, Operation and
Maintenance. Read and fully understand the information
before fitting, using and servicing the attachment. If there
is anything you do not understand, ask your JCB
distributor.
This section contains safety and cleanliness information

about Connecting/Disconnecting Hydraulic Hoses. This
information applies to all attachments which require a
hydraulic operating supply.
If your machine hydraulic system needs adapting to allow

the correct use of any auxiliary attachment, you must
consult your JCB distributor. Only trained hydraulic fitters
must re-route hydraulic hoses.
All optional attachments will have limits on their operation.

i.e. lifting capacity, speeds, hydraulic flow rates, etc.
Always check in the literature supplied with the
attachment and/or in the SPECIFICATION section of this
handbook. Some specification limits may also be
displayed on the attachment's Data/Rating Plate.
When fitting hydraulically driven attachments which have

been used on another machine, note that the hydraulic
fluids may not be of the same type. Residual fluid in the
attachment may not mix with the fluid in the machine and
damage may be caused.
4320-1

102
QUICK RELEASE COUPLINGS
Flat face quick release couplings allow the operator to ! WARNING

remove and install attachments swiftly and efficiently. The
Hydraulic fluid at pressure can injure you. Make the
Skid Steer Attachment pipework has two male couplings
machine safe before connecting or disconnecting
fitted. The attachment hoses have corresponding female
quick release couplings; stop the engine and operate
couplings fitted.
the attachment control a few times to vent residual
pressure.
The quick release couplings should be trouble free and 3-4-1-7
relatively easy to connect and disconnect, provided they
are kept clean and used correctly. The recommendations Before connecting or removing any hydraulic hose,
listed below should always apply when using flat face residual hydraulic pressure trapped in the service hose line
quick release couplings. must be vented (see Connecting/Disconnecting
Hydraulic Hoses).
Finally, please read the correct fitting and releasing
procedures before installing or removing any optional Connecting Quick Release Couplings
attachment fitted with quick release couplings.
1 Remove any residual hydraulic pressure trapped in
Quick Release Couplings - Do's & Don'ts the service line hose.
DO wipe the two faces of the coupling and make sure they 2 Wipe the two faces of the male and female couplings
are clean before connecting. and make sure they are clean.
DO make sure the outside sleeve (female coupling) is 3 Make sure that ball C in the female coupling is located
pulled back when disconnecting. in one of its slots.
DO connect and disconnect a new coupling two or three 4 Fit the male coupling into the female coupling. To
times to 'work' the PTFE seals - sometimes a new ensure that the coupling is not accidentally released,
coupling will stick if the seals have not been 'worked'. rotate sleeve E half a turn and make sure that the
locking ball C does not align with slot D.
DO use a spanner on the hexagon flats of the coupling
when fitting adaptors. Disconnecting Quick Release Couplings
DO use a rubber or hide hammer to disconnect a coupling
1 Release any residual hydraulic pressure trapped in the
if it sticks - sticking may occur if there is dirt present in the
service line hose.
coupling.
2 Align slot D with ball C.
DON'T attempt to re-connect a damaged half coupling -
this will destroy the seals and necessitate replacing both
3 Pull back sleeve E to release the coupling.
half couplings.
DON'T leave the coupling where it may be run over by a

machine or otherwise crushed - this will distort the
coupling sleeve and prevent correct connection and
disconnection.
DON'T clamp on the smooth diameter of the coupling

when fitting adaptors - always use the hexagon. C D
DON'T try to turn the sleeve (female coupling) when the
coupling has been disconnected - the locking ball will
wedge underneath the sleeve and destroy the coupling.
E
DON'T damage the faces of the couplings - this can
prevent connection and disconnection, or damage seals
and cause leakage.
DON'T try to dismantle the couplings - they are non S169490/1

serviceable parts. If a coupling is damaged it should be
replaced with a new one.
4320-1

103
CONNECTING/DISCONNECTING HYDRAULIC HOSES
Some attachments are hydraulically powered. The Disconnecting the Hoses

following paragraphs describe how to connect and
disconnect the hydraulic hoses safely. 1 Carry Out Steps 1 and 2 of Connecting the Hoses.
! WARNING 2 Disconnect the Hoses
Hydraulic fluid at pressure can injure you. Make the
machine safe before connecting or disconnecting See Disconnecting Quick Release Couplings on
quick release couplings; stop the engine and operate previous page.
the attachment control a few times to vent residual
pressure.
3-4-1-7
! WARNING
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check
Connecting the Hoses
for hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
1 Stop the Engine
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates
2 Relieve System Pressure
your skin, get medical help immediately.
INT-3-1-10/1
Operate the Auxiliary Attachment controls a few times.
This will release any hydraulic pressure trapped in the 3 Check for Leaks
hoses.
See Step 4 of Connecting the Hoses.
3 Connect the Hoses
See Connecting Quick Release Couplings on

previous page.
! WARNING
INT-3-1-10/1
4 Check for Leaks
a Start the engine.

b Operate the Auxiliary Control. This will build up
pressure in the hoses.
c Switch off the engine. Remove the starter key.
Check for signs of leakage at the hose
connections.
4320-1

104
ATTACHMENTS CONTROLS
Auxiliary Attachments Control Pedal

A four position rocker pedal A is used to actuate the
hydraulic function of an attachment. Press on either the
top or bottom of the pedal to operate. The pedal will
spring return to the central OFF position. A detent position
is also provided for attachments which require continuous A
operation, i.e. Sweeper. Press the bottom of the pedal to B
select the detent position.
The effect of pedal movement will depend on the way the

hydraulics are connected. Before using the attachment
operate the pedal to check the function.
The pedal is fitted with a lock to prevent accidental

operation. Slide the lock B to the left to secure the pedal in 378460
the central OFF position.
! WARNING
The auxiliary attachments control pedal must be locked
in its centre OFF position when no attachments are
fitted. Otherwise damage to the hydraulic system can
result due to overheating. Always engage the lock
BEFORE leaving or entering the cab.
3-2-1-12
Auxiliary Attachments Control Lever

(optional - manual machines)
As an option on manual machines, the right hand control
lever C may be used to actuate the hydraulic function of
C
an attachment. Move the lever to the left or right to
operate. The lever will spring return to the central OFF
position. A detent position may also be provided for
attachments which require continuous operation, i.e.
Sweeper.
The effect of lever movement will depend on the way the

hydraulics are connected. Before using the attachment
operate the lever to check the function.
332840
4320-1

105
SHOVELS
The following are some of the shovels that are available for Most attachments have an integral framework, such as the
the Skid Steer Loader. one shown below, to make them Quickhitch compatible.
Others such as the Earth drill, Hammer and compactor
General Purpose Shovel 0.50 m3 (17.66 ft3) require a separate frame, (see Attachment Frame).
0.60 m3 (21.19 ft3) Consult the relevant attachment literature or your JCB
Distributor as to the framework required.
Low Back Shovel 0.50 m3 (17.66 ft3)
0.60 m3 (21.19 ft3)
Low Back Dirt Shovel 0.50 m3 (17.66 ft3)

0.60 m3 (21.19 ft3)
6-in-1 Shovel 0.36 m3 (12.71 ft3)

0.40 m3 (14.13 ft3)
Contact your JCB Distributor for information on additional

shovels for special applications.
A174520
Typical Quickhitch Attachment Framework
6-IN-1 SHOVEL
The 6-in-1 shovel allows you to load, dig, grab, grade, Control
doze and spread without changing attachments.
The lift, lower, open and close movements of the 6-in-1
It is similar to a normal shovel except that it has an shovel are controlled by the loader control lever(s) (see
opening clam which is operated by hydraulic rams Loader Controls OPERATION section).
mounted on the bucket frame.
The shovel clam is operated either by a foot pedal, see
Safety Auxiliary Attachments Control Pedal, or by the right
hand control lever, see Auxiliary Attachments Control
Obey all the safety instructions given in the main part of Lever (optional - manual machines).
this book, plus those given in this section.
Operation
Practise using the 6-in-1 shovel off the job before working
with it for the first time.
Preparing for Travel

Close the clam then treat as a standard shovel.
4320-1

106
6-IN-1 SHOVEL
(continued)
Using the 6-in-1 Shovel

Always operate the controls slowly and carefully. Drive
slowly and carefully when the bucket is loaded. Keep the
shovel low to the ground when moving, this increases your
visibility and makes the machine more stable.
Loading and Digging
With the clam closed, the shovel can be used as a A174550

conventional shovel as described in Working with the
Loader. For higher dumping, open the clam instead of
rolling the shovel.
Grabbing
Open the clam and set the shovel directly above the
object to be grabbed. To grab the object, lower the shovel
and close the clam.
A174560
Grading
To grade, open the clam and drag the shovel backwards.

When the shovel is full, roll it back and close the clam.
A174570
Dozing
To doze, open the clam and drive the machine forward.
A174580
Spreading
Load the shovel with the material to be spread. Set the

clam opening to suit the size of material and rate of flow.
Drag the shovel backwards, allowing it to discharge an
even layer of material as it goes.
A174590
4320-1

107
6-IN-1 SHOVEL
(continued)
Daily Maintenance
1 Clean with the rest of the machine.
2 Check for damage. 1

3 Check for signs of hydraulic leaks in hoses, adapters,
rams.
! WARNING
INT-3-1-10/1
4 Grease
Total of 4 grease points. (1 and 2 as illustrated, 3 and 2 A174600

4 at opposite end.)
4320-1

108
PALLET FORKS
The pallet fork frame includes a Rating Plate which gives Road Travel
its weight and its Safe Working Load.
! WARNING
The forks should always be used in pairs as supplied.
The Quickhitch forks must not be fitted for road travel.
Each fork is stamped with its Part Number and Safe
Failure to comply may render the operator vulnerable
Working Load.
to criminal prosecution. If the machine has to travel on
public roads the forks must be removed.
! CAUTION 2-4-5-4
The Safe Working Load stamped on each fork is for
the fork itself. It is not for the machine to which the
fork may be fitted. Before lifting any load check the Adjust the Fork Spacing
weight of the load against the Safe Working Load of
the machine. 1 Position the forks until they are just clear of the
2-4-5-3
ground.
2 Move the spring-loaded locking lever to the vertical

Safety position A and slide the fork along the rail.
Obey all the safety instructions given in the main part of 3 When the fork is in the required position return the
this book, plus the ones given in this section. spring-loaded locking lever to the horizontal position
B, ensuring that the locking pin is fully engaged in a
An optional Load Guard can be purchased, see your JCB slot in the rail.
Distributor for details.
! WARNING
Forklift operation is a specialised area of materials
handling. If forks are fitted to the Quickhitch then
operator training is recommended and, in some
territories, a legal requirement.
A
Failure to comply may render the operator vulnerable
to criminal prosecution.
2-4-5-1
! CAUTION B
Loads can fall off incorrectly spaced forks. Always B
space the forks correctly for the load. Make sure the
forks are completely under the load before lifting.
5-1-4-2
Fitting/Removing Pallet Forks

See Quickhitch Control (OPERATION section).
Operation
A174610
Practise using the forks off the job before working with
them for the first time. Daily Maintenance
Control 1 Oil the spring loaded locking lever.
The forks are operated by the loader control lever (see 2 Grease top rail slots.
Loader Controls (OPERATION section).
3 Clean with the rest of the machine.
Operate the control carefully when using the forks.
4320-1

109
MANURE/SILAGE FORK WITH TOP GRAB
The Manure/Silage fork is fitted with a top grab as Daily Maintenance

standard which gives extra security to the pay load when
moving the machine. 1 Clean with the rest of the machine.
The grab is opened and closed by a hydraulic ram 2 Check for damage
mounted on the fork frame.
Make sure the tines are secure and in good condition.
Safety
3 Check for signs of hydraulic leaks
Obey all the safety instructions given in the main part of
this book, plus those given in this section. ! WARNING
Operation penetrate the skin. Do not use your fingers to check
Practise using the Manure/Silage fork "off the job" before suspected leaks. Hold a piece of cardboard close to
working with it for the first time. suspected leaks and then inspect the cardboard for
Control your skin, get medical help immediately.
INT-3-1-10/1
The lift, lower and tilt movements of the fork are controlled
4 Grease
by the loader control lever (see Loader Controls
OPERATION section).
Total of 5 grease points.
The grab is operated either by a foot pedal, see Auxiliary
Attachments Control Pedal, or by the right hand control
lever, see Auxiliary Attachments Control Lever (optional
- manual machines).
Preparing for Travel

2 3
Close the grab; then treat as a standard shovel.
1
Installing and Removing 5
Apart from connecting and disconnecting the hydraulic
hoses, the Manure/Silage fork is installed like a standard
bucket. See Quickhitch Control in OPERATION section. 4
Close the grab before removing it.
Using the Manure/Silage Fork

Always operate the controls slowly and carefully. Drive
slowly and carefully when the Manure/Silage fork is
loaded. Keep the fork low to the ground when moving, this
A174620
increases your visibility and makes the machine more
stable.
Open the top grab before loading the fork. Close the top
grab on the load before moving the machine.
To unload the fork, raise it to a suitable height, open the

top grab and tilt down.
4320-1

110
ATTACHMENT FRAME
Some attachments, e.g. Hammermaster and Earth Drill,

utilise an attachment frame for installing on a Skid Steer
Loader. Use the following procedure for
Installing/Removing the attachment frame.
Installing/Removing the Attachment

Frame
1 Stand the attachment frame on level ground as shown 6 Push Quickhitch levers fully in, as at position E, to
at A. Drive the Skid Steer Loader squarely up to the engage locking pins F and secure the attachment
frame and stop. frame.
2 Lower the loader arm and tilt forward Quickhitch plate 7 Removal is the reversal of steps 1 to 5 above.
B so that the top of the plate is lower than the lip C of
the attachment frame. 8 Refer to the Owners Manual of the particular
attachment for full instructions concerning its
! WARNING installation/removal from the attachment frame.
levers. If the controls are moved accidentally you
could be killed or injured.
3-4-1-8 A
3 Move Quickhitch levers (one each side of hitch plate) C
fully out, as at position D.
4 Drive the machine forward until the Quickhitch plate

touches the attachment frame then stop.
5 Slowly tilt the plate backwards until it engages the

attachment frame lip. Raise the loader arm until the
frame is in contact with the Quickhitch plate, top and
bottom. A174630
F
F 378670
4320-1

111
WHEEL MOUNTED TRACKS
Some machines are supplied with metal tracks which fit

over the tyres for improved flotation. These machines are
fitted with wheel spacers and modified cab/canopy step
and door to give clearance for the track. The tracks must
only be fitted over pneumatic tyres.
Installing the Tracks 1
1 Lay out one of the tracks on firm level ground and

drive the machine onto the track. Stop the machine
with the rear tyre just past the last pad.
2 Get a helper to hold the last pad against the rear tyre 2
taking care not to pinch their fingers in the track or
machine. Alternatively, tie the last pad to the rear
wheel. Drive the machine slowly forwards, stop when
the track will connect between the wheels at the top.
3 Lift the front section of the track over the front tyre. 3
Install the web binder so it will pull on the first bar of
the second pad on each end as shown at D.
366180
4 Pull the ends together and install bolts A both sides of

the track in the long holes B or short holes C as
required to achieve the correct tension.
5 Position a straight edge on top of the track and

measure clearance E which should be approximately
25 mm (1in). If the track is still too loose with the bolts
in the short holes move the bolts in the adjacent pad
into the short position. Continue moving the bolts in E
each pad until the correct tension is obtained.
Note: It is better for performance and cleaning if only one

pair of bolts per pad is moved so that the bars are not 315970
bunched together.
315980
B
315960
A
315890
C
315950
4320-2

112
WHEEL MOUNTED TRACKS

(continued)
Installing the Tracks (cont’d) Operating Hints

6 Secure the bolts with the nuts provided. Keep the track adjusted closer to the recommended 25
mm (1in) clearance when conditions are such that the
7 Fit the other track in the same way. tyres slip inside the track or the track hits the underside of
the fender. Do not overtighten the track otherwise the
8 With both sides installed, drive the machine slowly in tyres will be damaged.
both directions then re-check the track tension. Make
further adjustments as required. The tension may not During the first few days of use, check the track frequently
be the same on both sides of the machine due to to see that all bolts stay tight and no damage is being
small differences in the diameter of the tyres. caused to the tyres or machine.
Continue to test the machine until it can be driven at
maximum speed without the tracks hitting the fenders. If a tyre deflates suddenly for no apparent reason it could
be caused by an object coming between the tyre and the
! CAUTION track and breaking the seal at the tyre bead. This can be
eliminated by putting a tube in the tyre.
On machines with 2 speed drive motors, do not select
high speed when wheel mounted tracks are fitted as
If the tyre tread is badly worn the wheel may spin inside
0092 the track. Do not fit oversize tyres otherwise the track may
not fit properly and damage the tyre. Inflate the tyres to
the normal recommended pressures.
Removing the tracks
If the tracks are muddy they should be cleaned by
washing or by driving the machine through water before
removal. If mud is allowed to build up and dry in the track
joints it can cause the track to kink.
If the tracks are to be stored in the laid out position as

they come off the machine then move the machine to the
storage area. If the tracks are to be rolled up and put on
pallets it is best to move the machine to a hard surface.
The track can be taken apart at any pad as all pads are
the same.
1 Partially raise and support the carriage to give

clearance at the front wheels.
2 Remove the nuts from one pair of bolts on each track

2
at the position shown and partially drive the bolts out
until the threaded ends are flush with the pad.
3 Drive the machine slowly forward until the bolts to be

removed are at the bottom between the wheels.
4 Withdraw the bolts by unscrewing them with a 3

wrench.
5 Drive the machine slowly forwards off the tracks.
6 If the track is to be rolled up for storage it is better

positioned on its edge before rolling. Secure the ends
with wire. Put the loose hardware in the ends of the
track to prevent loss.
5
366190
4320-3

131
SPECIFICATION 131
GENERAL SPECIFICATION
190 wheeled 190 tracked 1110 wheeled 1110 tracked

kg (lb) kg (lb) kg (lb) kg (lb)
Rated operating capacity

with standard bucket 900 (1984) 1320 (2911) 1100 (2425) 1460 (3219)
SAE tipping load

with standard bucket 1800 (3969) 2570 (5667) 2200 (4851) 2915 (6428)
Total weight
(inc. standard bucket) 3500 (7717) 4400 (9702) 3725 (8214) 4625 (10198)
Weight distribution
(unloaded) front/rear % 30/70 30/70 30/70 30/70
TYRE SPECIFICATION
Pneumatic tyres size pressure - bar (lbf/in2)

Omega HD 12 x 16.5, 10 Ply 3.5 (50)
Omega HD WT 12 x 16.5, 10 Ply 3.5 (50)
Solideal 12 x 16.5, 12 Ply 3.5 (50)
Solideal 33/15.5 x 16.5, 14 Ply 4.0 (60)
Non-inflatable tyres (on special rim)
Airboss 8.25 x 15 & 12 x 16.5
Solids 8 x 16
4320-3

132
SPECIFICATION 132
STATIC DIMENSIONS - WHEELED MACHINES
A Overall length (including Quickhitch) 2742 mm (108 in)
B Overall length (including standard shovel) 3500 mm (138 in)
C Height 2015 mm (79 in)
D Width over tyres (12 x 16.5) 1690 mm (67 in)
Width over tyres (8.00 x 16) 1792 mm (71 in)
E Ground clearance 255 mm (10 in)
F Wheel base 1125 mm (44 in)
G Maximum pin height 3114 mm (122.5 in)
H Shovel roll back angle (from horizontal) 30°
J Shovel dump angle at maximum height 40°
K Shovel maximum lift height 2955 mm (116 in)
L Shovel dump height at maximum dump angle 2423 mm (95 in)
M Shovel reach at maximum dump angle 630 mm (25 in)
N Shovel reach at ground level 1004 mm (39.5 in)
O Shovel reach at maximum height 941 mm (37 in)
P Shovel width (standard) 1879 mm (74 in)
4320-1

133
SPECIFICATION 133
STATIC DIMENSIONS - WHEELED MACHINES

(continued)
G
K M
L
C
N F E
A
B
P D
378310
4320-1

134
SPECIFICATION 134
STATIC DIMENSIONS - TRACKED MACHINES
A Overall length (including Quickhitch) 2742 mm (108 in)
B Overall length (including standard shovel) 3500 mm (138 in)
C Height 2030 mm (80 in)
D Width over 320 mm tracks 1830 mm (72 in)
Width over 450 mm tracks 1960 mm (77 in)
E Ground clearance 270 mm (10.6 in)
F Maximum pin height 3130 mm (123 in)
G Shovel roll back angle (from horizontal) 30°
H Shovel dump angle at maximum height 40°
J Shovel maximum lift height 2969 mm (117 in)
K Shovel dump height at maximum dump angle 2439 mm (96 in)
L Shovel reach at maximum dump angle 655 mm (26 in)
M Shovel reach at ground level 1027 mm (40.4 in)
N Shovel reach at maximum height 965 mm (38 in)
O Shovel width (standard) 1879 mm (74 in)
4320-1

135
SPECIFICATION 135
STATIC DIMENSIONS - TRACKED MACHINES

(continued)
F
J
K L
C
M E
A
B
O D
378320
4320-1

136
SPECIFICATION 136
NOISE AND VIBRATION DATA
Machines up to serial no. 888055
NOISE - WHEELED MACHINES Robot 190 Robot 1110

Canopy Cab Canopy Cab
1 Noise Level at Operator's Ear (LpA) 91.0 91.0 91.0 91.0
2 External Noise Level (LwA) 104.0 103.0 104.0 103.0
NOISE - TRACKED MACHINES Robot 190 Robot 1110

Canopy Cab Canopy Cab
1 Noise Level at Operator's Ear (LpA) 91.0 91.0 91.0 91.0
2 External Noise Level (LwA) <106.0 <106.0 <107.0 <107.0
VIBRATION
3 Weighted rms acceleration : Whole Body (m/s2) Wheeled machines : 1.6 Tracked machines : 1.7
4 Weighted rms acceleration : Hand/Arm (m/s2) Servo machines : <2.5 Manual Machines : 6
Items 1 and 2 above determined in accordance with dynamic test conditions defined in 86/662 EEC as amended by
95/27/EC.
Item 3 above is an "Average Equivalent Value" determined from measurement on machines performing typical duties
detailed below, with values weighted in accordance with ISO 2631.
Item 4 above measured at the steering control device when machine is travelling over rough terrain, with values weighted in
accordance with ISO 2631.
The Vibration values are determined from measurements in three perpendicular planes.
Values determined with rehandling bucket fitted.
For information relating to this machine when used with other JCB approved attachments, please refer to the literature
accompanying the attachments.
Typical Duties for Robot machine: Roading (Tarmac)

Roading (Rough Terrain)
Rehandling cycles (including roading type duties)
4320-2

137
SPECIFICATION 137
NOISE AND VIBRATION DATA
Machines from serial no. 888056
The noise data below only applies to CE marked machines
NOISE - WHEELED MACHINES Robot 190 Robot 190HF Robot 1110 Robot 1110HF
Canopy Cab Canopy Cab Canopy Cab Canopy Cab
1 Noise Level at Operator's Ear (LpA) 88.0 91.0 91.0 91.0 91.0 91.0 91.0 91.0
2 External Noise Level -

Guaranteed Sound Power Level (LwA) 104.0 104.0 104.0 104.0 104.0 104.0 105.0 105.0
NOISE - TRACKED MACHINES Robot 190 Robot 190HF Robot 1110 Robot 1110HF
Canopy Cab Canopy Cab Canopy Cab Canopy Cab
1 Noise Level at Operator's Ear (LpA) 91.0 91.0 91.0 91.0 91.0 91.0 91.0 91.0
2 External Noise Level -

Guaranteed Sound Power Level (LwA) 106.0 106.0 106.0 106.0 106.0 106.0 107.0 107.0
VIBRATION
3 Weighted rms acceleration : Whole Body (m/s2) Wheeled machines : 1.6 Tracked machines : 1.7
4 Weighted rms acceleration : Hand/Arm (m/s2) Servo machines : <2.5 Manual Machines : 6
Item 1 above determined in accordance with dynamic test conditions defined in ISO 6396.
Item 2 above determined in accordance with dynamic test conditions defined in 2000/14/EC (Annex 5, 6).
Item 3 above is an "Average Equivalent Value" determined from measurement on machines performing typical duties
detailed below, with values weighted in accordance with ISO 2631.
Item 4 above measured at the steering control device when machine is travelling over rough terrain, with values weighted in
accordance with ISO 2631.
The Vibration values are determined from measurements in three perpendicular planes.
Values determined with rehandling bucket fitted.
Typical Duties for Robot machine: Roading (Tarmac)

Roading (Rough Terrain)
Rehandling cycles (including roading type duties)
4320-1


SERVICE RECORD SHEET
5000 Hrs./60 Months
Distributor Preparation Annual Insurance & Shackle
Despatch Sheet Inspection (UK only)
Date .............................
Date .............................
Hour reading ................
First 100 Hours Only 5500 Hrs./66 Months
Date ............................. Date .............................
Hour reading ................ Hour reading ................
500 Hrs./6 Months 6000 Hrs./72 Months

Annual Insurance & Shackle
Inspection (UK only)
Date .............................
Date .............................
Date .............................
Date .............................
Hour reading ................
Hour reading ................
1500 Hrs./18Months 7000 Hrs./84 Months
Date .............................
Date .............................
Date .............................
Date .............................

Date .............................
Date .............................
Hour reading ................
Hour reading ................
Date .............................
Date .............................

Date .............................
Date .............................
Date .............................
Date .............................
Hour reading ................
Hour reading ................
10000 Hrs./120 Months
4500 Hrs./54 Months Annual Insurance & Shackle
Date .............................
Date .............................
4320-1


REGISTRATION INFORMATION (Do not remove this portion from the Handbook) Issue 3 February 2000
English
Registration Date ............................................................... Dealer ..............................................................................
P.I.N/Machine Serial Number !!!!!!!
V.I.N. S L P
!!!!!!!!!!!!!!!!! JCB Model ........................................................................... Installing Engineer ........................................................
Vehicle Registration Number !!!!!!! Eng. Ser. No. !!!!!!!!!!!!!!!!! Signature ........................................................................
#
DEALERS COPY U.K. and EIRE ONLY
Do NOT send back to JCB SERVICE A COPY OF THE REGISTRATION DETAILS TO BE SENT DIRECT TO:-
Dealer ....................................................................................................................... THE EQUIPMENT REGISTER LTD. (T.E.R.),

JCB Model ............................................................................................................... BATH & WEST BUILDINGS
LOWER BRISTOL ROAD
P.I.N/Machine Serial Number !!!!!!! BATH
V.I.N. S L P
!!!!!!!!!!!!!!!!! BA2 3EG
Vehicle Registration Number !!!!!!!
Tel: 01225 464599 (24 Hour) Fax: 01225 317698
Engine Serial Number !!!!!!!!!!!!!!!!!
Customer's Name ...................................................................................................
Address ...................................................................................................................
....................................................................................................................................
............................................................................Postcode .....................................
Registration Date ....................................................................................................
Installing Engineer ..................................................................................................
P.D.I. Date ................................................................................................................
Owner's Plant Reference No. ................................................................................
ALPHA • DOT SECURITY SYSTEM - YES/NO

" Please send details of:
“JCB Assetcare Machinery Protection Plan” !

#


*9801/4320*
9801/4320

Robot 190 & 1110 Op - Manuals

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ROBOT 190, 190HF, 1110, 1110HF

! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES !

Publication Number 9801/4320 January 2002 Issue 4

Purchased from www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Vandalism and theft of unattended machines is an ever increasing problem and

JCB PLANTGUARD is a comprehensive package available to help you safeguard

Your JCB Distributor or Dealer will be pleased to provide information on any of

Purchased from www.WorkshopManuals.co.uk

INTRODUCTION Page Page

About this Handbook Cab Heater Unit (optional) ..................................... 33

JCB Immobiliser Option ........................................ 10 Travelling Position

Introduction ............................................................ 21 Driving the Machine

Emergency Exits .................................................... 24 Quickhitch Control

Seat Belt Moving a Disabled Machine

Purchased from www.WorkshopManuals.co.uk

OPERATION (cont’d) Page Page

Transporting the Machine Greasing (50 Hours)

Engine Oil and Filter

Service Schedules Drive Chain Lubrication

Purchased from www.WorkshopManuals.co.uk

MAINTENANCE (cont’d) Page

Windscreen Washer ............................................... 87

Tyres and Wheels

Fluids, Capacities and Lubricants ........................ 89

Obtaining Replacement Parts ................................ 89

OPTIONAL ATTACHMENTS Page

Introduction ........................................................... 101

Quick Release Couplings ..................................... 102

Connecting/Disconnecting Hydraulic Hoses ..... 103

Attachments Controls ............................................ 104

Shovels .................................................................... 105

6-in-1 Shovel ............................................................ 105

Pallet Forks .............................................................. 108

Manure/Silage Fork with Top Grab ........................ 109

Attachment Frame ................................................... 110

Wheel Mounted Tracks ........................................... 111

General Specification ............................................. 131

Tyre Specification ................................................... 131

Static Dimensions - Wheeled Machines ................ 132

Static Dimensions - Tracked Machines ................ 134

Noise and Vibration Data

Purchased from www.WorkshopManuals.co.uk

ABOUT THIS HANDBOOK

Machine Models Page Numbering

General warnings in this chapter are repeated throughout

Finally, treat this handbook as part of the machine. Keep it

Purchased from www.WorkshopManuals.co.uk

THE JCB SKIDSTEER LOADER

When used normally with a shovel FUEL QUICKHITCH

REAR WORKING LIGHT

HYDRAULIC HYDRAULIC SIGHT GLASS

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SAFETY FIRST - YOURS AND OTHER PEOPLE'S

SAFETY CHECK LIST

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SAFETY CHECK LIST

General Safety (continued)