JCB 9831 1850 4 Om en

OPERATOR'S MANUAL
LOADER
411HT, 413S, 417HT
EN - 9831/1850 ISSUE 4 - 03/2018
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

Foreword
The Operator's Manual
You and others can be killed or seriously injured

if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
OPERATOR'S Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
MANUAL do not understand.
Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
LOADER Machine Delivery and Installation

411HT, 413S, 417HT
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain

maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the

Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
EN - 9831/1850 - ISSUE 4 - 03/2018
This manual contains original instructions, verified by

the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE

All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Find manuals at https://best-manuals.com

Notes:
9831/1850-4

Table of Contents
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vii
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cab/Canopy .......................................................................................................................................... 1
Cross References ................................................................................................................................. 2
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product

Introduction
General .................................................................................................................................................. 7
Name and Address of the Manufacturer .............................................................................................. 7
Product Compliance .............................................................................................................................. 7
Description
General .................................................................................................................................................. 8
Intended Use ......................................................................................................................................... 8
Log Moving/Object Handling ................................................................................................................. 8
Optional Equipment and Attachments .................................................................................................. 8
Danger Zone ......................................................................................................................................... 8
Main Component Locations .................................................................................................................. 8
Product and Component Identification
Machine ............................................................................................................................................... 10
Engine ................................................................................................................................................. 10
Operator Protective Structure ............................................................................................................. 11
Safety Labels
General ................................................................................................................................................ 13
Safety Label Identification ................................................................................................................... 13
Operator Station
Component Locations ......................................................................................................................... 16
Interior Switches
Ignition Switch ..................................................................................................................................... 17
Multi-Purpose Switch .......................................................................................................................... 17
Cab Interior Light ................................................................................................................................ 18
Console Switches
General ................................................................................................................................................ 20
Operation
Introduction
General ................................................................................................................................................ 23
Operating Safety
General ................................................................................................................................................ 24
Worksite Safety ................................................................................................................................... 26
Risk Assessment ................................................................................................................................ 27
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Table of Contents
Walk-Around Inspection
General ................................................................................................................................................ 29
Entering and Leaving the Operator Station
General ................................................................................................................................................ 30
Emergency Exit ................................................................................................................................... 30
Doors
Operator Door ..................................................................................................................................... 32
Windows
Side Window ....................................................................................................................................... 33
Battery Isolator
General ................................................................................................................................................ 34
Before Starting the Engine
General ................................................................................................................................................ 35
Operator Seat
General ................................................................................................................................................ 37
Armrest ................................................................................................................................................ 40
Seat Belt
General ................................................................................................................................................ 42
Inertia Reel Seat Belt ......................................................................................................................... 42
Mirrors
General ................................................................................................................................................ 44
Visual Aids
Exterior View System .......................................................................................................................... 48
Starting the Engine
General ................................................................................................................................................ 51
Stopping and Parking
General ................................................................................................................................................ 52
Preparing for Travel
General ................................................................................................................................................ 54
Preparing for Road Travel .................................................................................................................. 54
Preparing for Worksite Travel ............................................................................................................. 55
Smooth Ride System (SRS) ............................................................................................................... 56
Beacon ................................................................................................................................................ 57
Safety Equipment
Articulation Lock .................................................................................................................................. 58
Control Lock ........................................................................................................................................ 59
Drive Controls
General ................................................................................................................................................ 60
Steering Wheel ................................................................................................................................... 65
Steering Column ................................................................................................................................. 65
Accelerator Pedal ................................................................................................................................ 65
Forward, Neutral and Reverse Switch ................................................................................................ 66
Service Brake Pedal ........................................................................................................................... 67
Park Brake .......................................................................................................................................... 67
Transmission Kickdown Switch ........................................................................................................... 68
Instruments
Instrument Panel ................................................................................................................................. 70
Getting the Machine Moving
General ................................................................................................................................................ 78
Slopes
General ................................................................................................................................................ 79
ii 9831/1850-4 ii

Table of Contents
Driving on Slopes ............................................................................................................................... 79

Working on Slopes ............................................................................................................................. 80
Driving the Machine
Towing Other Equipment .................................................................................................................... 81
Operating Levers/Pedals
General ................................................................................................................................................ 82
Control Layouts ................................................................................................................................... 82
Lift Arm Controls ................................................................................................................................. 82
Auxiliary Circuit Controls ..................................................................................................................... 83
Lifting and Loading
General ................................................................................................................................................ 86
Working with the Lift Arm
General ................................................................................................................................................ 87
Filling the Shovel ................................................................................................................................ 88
Loading a Truck .................................................................................................................................. 88
Adjusting the Lift Arm ......................................................................................................................... 89
Heating, Ventilating and Air-Conditioning (HVAC)
General ................................................................................................................................................ 92
Air-Conditioning Controls .................................................................................................................... 92
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 94
Fire Extinguisher
General ................................................................................................................................................ 95
Moving a Disabled Machine
General ................................................................................................................................................ 96
Getting the Machine Unstuck ............................................................................................................. 96
Jump-Starting the Engine ................................................................................................................... 96
Retrieval .............................................................................................................................................. 97
Loader Arm (Emergency Operation) ................................................................................................ 100
Lifting the Machine
General .............................................................................................................................................. 101
Transporting the Machine
General .............................................................................................................................................. 103
Operating Environment
General .............................................................................................................................................. 105
Operating in Low Temperatures ....................................................................................................... 105
Operating in High Temperatures ....................................................................................................... 106
Cab Filters ......................................................................................................................................... 106
Refuelling
General .............................................................................................................................................. 107
Low Fuel Levels ................................................................................................................................ 107
Filling the Tank .................................................................................................................................. 107
Attachments
Working with Attachments
Introduction ........................................................................................................................................ 109
Attachments for your Machine .......................................................................................................... 109
Connecting/Disconnecting Hydraulic Hoses ..................................................................................... 110
Quickhitch
General .............................................................................................................................................. 114
Lift Arm Quickhitch Carriage ............................................................................................................ 114
iii 9831/1850-4 iii

Table of Contents
Tow Hitches
Hydraulic Tow Hitch .......................................................................................................................... 119
Work Platforms
General .............................................................................................................................................. 125
Preservation and Storage

Cleaning
General .............................................................................................................................................. 127
Preparation ........................................................................................................................................ 128
Checking For Damage
General .............................................................................................................................................. 129
Storage
General .............................................................................................................................................. 130
Put into Storage ................................................................................................................................ 130
During Storage .................................................................................................................................. 130
Take out of Storage .......................................................................................................................... 131
Security
General .............................................................................................................................................. 132
JCB Plantguard ................................................................................................................................. 132
Construction Equipment Security and Registration Scheme (CESAR) ............................................ 132
LiveLink ............................................................................................................................................. 132
Maintenance
Introduction
General .............................................................................................................................................. 133
Owner/Operator Support ................................................................................................................... 133
Service/Maintenance Agreements .................................................................................................... 134
Initial Service and Inspection ............................................................................................................ 134
Obtaining Spare Parts ...................................................................................................................... 134
Maintenance Safety
General .............................................................................................................................................. 135
Fluids and Lubricants ....................................................................................................................... 136
Maintenance Schedules
General .............................................................................................................................................. 140
How to Use the Maintenance Schedules ......................................................................................... 140
Maintenance Intervals ....................................................................................................................... 140
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................. 141
Functional Tests and Final Inspection .............................................................................................. 143
Maintenance Positions
General .............................................................................................................................................. 145
Maintenance Position (Lift Arm Lowered) ........................................................................................ 145
Maintenance Position (Lift Arm Raised) ........................................................................................... 146
Service Points
General .............................................................................................................................................. 148
Access Apertures
General .............................................................................................................................................. 150
Battery Cover .................................................................................................................................... 150
Engine Compartment Cover ............................................................................................................. 150
Cab Heater Door .............................................................................................................................. 151
Tools
General .............................................................................................................................................. 153
Toolbox .............................................................................................................................................. 153
iv 9831/1850-4 iv

Table of Contents
Lubrication
General .............................................................................................................................................. 154
Preparation ........................................................................................................................................ 154
Automatic Greasing System ............................................................................................................. 154
Attachments
General ............................................................................................................................................. 156
Body and Framework
General ............................................................................................................................................. 157
Lift Arm
General ............................................................................................................................................. 158
Operator Station
General ............................................................................................................................................. 159
Operator Protective Structure ........................................................................................................... 159
Seat ................................................................................................................................................... 159
Seat Belt ........................................................................................................................................... 159
Controls ............................................................................................................................................. 160
Air-Conditioning ................................................................................................................................ 161
Heater ............................................................................................................................................... 161
Engine
General ............................................................................................................................................. 163
Oil ...................................................................................................................................................... 163
Drive Belt .......................................................................................................................................... 165
Crankcase Ventilation ....................................................................................................................... 166
Exhaust ............................................................................................................................................. 166
Emissions Control System ............................................................................................................... 166
Air Filter
General ............................................................................................................................................. 171
Outer Element .................................................................................................................................. 171
Pre-Cleaner ....................................................................................................................................... 173
Fuel System
General ............................................................................................................................................. 174
Fuel Filter .......................................................................................................................................... 174
Water Separator ............................................................................................................................... 174
Cooling System
General ............................................................................................................................................. 176
Coolant .............................................................................................................................................. 176
Cooling Pack .................................................................................................................................... 176
Brakes
General .............................................................................................................................................. 178
Service Brake ................................................................................................................................... 178
Gearbox
Oil ...................................................................................................................................................... 179
Steering System
General ............................................................................................................................................. 180
Driveshafts
General ............................................................................................................................................. 181
Wheels
General ............................................................................................................................................. 182
Tyres
General ............................................................................................................................................. 184
v 9831/1850-4 v

Table of Contents
Hydraulic System
General ............................................................................................................................................. 186
Services ............................................................................................................................................ 187
Oil ...................................................................................................................................................... 187
Cylinders / Rams .............................................................................................................................. 188
Hose Burst Check Valves ................................................................................................................. 188
Electrical System
General ............................................................................................................................................. 189
Battery ............................................................................................................................................... 189
Battery Isolator ................................................................................................................................. 191
Fuses ................................................................................................................................................ 191
Relays ............................................................................................................................................... 193
Window Washer ................................................................................................................................ 194
Miscellaneous
Fire Extinguisher ............................................................................................................................... 196
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 197
Performance Dimensions
Lift Arm Dimensions and Performance ............................................................................................. 200
Driving Performance ......................................................................................................................... 201
Towing Weights ................................................................................................................................. 203
Noise Emissions
General .............................................................................................................................................. 204
Noise Data ........................................................................................................................................ 204
Vibration Emissions
General .............................................................................................................................................. 205
Vibration Data ................................................................................................................................... 206
Fluids, Lubricants and Capacities
General .............................................................................................................................................. 207
Fuel ................................................................................................................................................... 210
Diesel Exhaust Fluid (DEF) .............................................................................................................. 213
Coolant .............................................................................................................................................. 215
Torque Values
General .............................................................................................................................................. 216
Electrical System
General .............................................................................................................................................. 217
Bulbs ................................................................................................................................................. 217
Fuses ................................................................................................................................................. 217
Relays ............................................................................................................................................... 220
Engine
General .............................................................................................................................................. 222
Exhaust After Treatment (EAT) ......................................................................................................... 222
Wheels and Tyres
General .............................................................................................................................................. 226
Tyre Sizes and Pressures ................................................................................................................ 226
Declaration of Conformity
General .............................................................................................................................................. 229
Data ................................................................................................................................................... 229
Warranty Information
Service Record Sheet ....................................................................................................................... 231
vi 9831/1850-4 vi

Table of Contents
Acronyms Glossary
ARV Auxiliary Relief Valve

ATC Automatic Temperature Control
CCV Crankcase Ventilation
CESAR Construction Equipment Security and Registration
DEF Diesel Exhaust Fluid
ECU Electronic Control Unit
ETRTO European Tyre and Rim Technical Organisation
FOPS Falling Object Protective Structure
HVAC Heating Ventilation Air Conditioning
ISO International Organization for Standardization
LCD Liquid Crystal Display
LED Light Emitting Diode
MRV Main Relief Valve
PIN Product Identification Number
PPE Personal Protective Equipment
RMS Root Mean Square
ROPS Roll-Over Protective Structure
SCR Selective Catalytic Reduction
SRS Smooth Ride System
vii 9831/1850-4 vii

Notes:
viii 9831/1850-4 viii

Introduction
About this Manual
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
411HT 2420001 2420200
413S 2420201 2420400
417HT 2420401 2420600
2702321
Using the Manual

This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.
If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.
The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
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 manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side

In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.
Figure 1.
B
A
A Left B Right
Cab/Canopy
This manual frequently makes references to the cab. For example, 'do not operate the machine without an
operator's manual in the cab'. These statements also apply to canopy build machines.
1 9831/1850-4 1
Introduction
About this Manual
Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References (Page 2).
Location of Manual
The manual is located in the case attached to the back of the seat. The manual should always be returned
to its case after use.
Figure 2.
A Manual location B Operator seat
2 9831/1850-4 2
Introduction
Safety
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, you must read and understand them. They
inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages,
ask your employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
Safety Warnings
In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are
given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system symbol (shown) also helps to identify important safety messages in this manual. When
you see this symbol your safety is involved, carefully read the message that follows.
Figure 3. The safety alert system symbol
3 9831/1850-4 3
Introduction
Safety
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. Ensure that
you receive the correct training before operating any machinery. Failing to do so will result in incorrect operation
of the machine and you will be putting yourself and others at risk. In some markets, and for work on certain
jobsites, you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements – it
is your responsibility.
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.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself
and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.
4 9831/1850-4 4
Introduction
Safety
Clothing and Personal Protective Equipment (PPE)

Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.
5 9831/1850-4 5
Notes:
6 9831/1850-4 6
About the Product
Introduction
About the Product

Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
JCB Earthmovers Limited, Harewood Estate, Leek Road, Cheadle, Stoke On Trent, Staffordshire, United
Kingdom, ST10 2JX
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.
7 9831/1850-4 7
About the Product
Description
Description
General
A self-propelled wheeled machine with an integral front mounted shovel-supporting structure and linkage.
The machine can load or excavate through the forward motion of the machine, and can lift, transport and
discharge material.
Intended Use
The machine is intended to be used in normal conditions for the applications described in this manual.
If the machine is used for other applications or in dangerous environments, for example in a flammable
atmosphere or in areas with dust containing asbestos, special safety regulations must be obeyed and the
machine must be equipped for use in these environments.
Log Moving/Object Handling

Do not use the machine to move or handle logs unless sufficient log protection is installed. You could cause
serious injury to yourself and damage to the machine. For more information, contact your JCB dealer.
Optional Equipment and Attachments

A wide range of optional attachments are available to increase the versatility of your machine. Only the JCB
approved attachments are recommended for use with your machine. Contact your JCB dealer for the full list
of approved attachments available.
Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. The danger zone includes the area in immediate proximity to any hazardous moving parts,
areas into which working equipment and attachments can be moved to quickly, the machine normal stopping
distances and also areas into which the machine can quickly turn under normal conditions of use. Depending
on the application at the time, the danger zone could also include the area into which debris, from use of an
attachment or working tool, could be projected and any area into which debris could fall from the machine.
During the operation of the machine, keep all persons out of the danger zone. Persons in the danger zone
could be injured.
Before you do a maintenance task, make the product safe.
Main Component Locations
8 9831/1850-4 8
About the Product
Description
Figure 4.
C
L F A
A Loader arms B Quickhitch (option)

C ROPS (Roll-Over Protective Structure)/FOPS D Engine cover
(Falling Object Protective Structure) cab
E Hydraulic fluid filler point F Hydraulic fluid tank sight glass
G Diesel filler point H Articulation lock
J Battery K Battery isolator switch
L Maintenance struts (option) M Transmission fill
9 9831/1850-4 9
About the Product

Machine
Your machine has an identification plate. The PIN (Product Identification Number), weight, engine power, year
of manufacture and serial number of the machine are shown on the identification plate.
The serial number of each major unit is also shown on the unit itself. If a major unit is replaced by a new one,
the serial number on the identification plate will be wrong. Either get a replacement identification plate from
your JCB dealer or simply remove the old number. This will prevent the wrong unit number being quoted when
replacement parts are ordered.
Figure 5.
A
A Identification plate (location)
The machine model and build specification are indicated by the PIN. The PIN has 17 digits and must be read
from left to right.
Table 1. Typical PIN

JCB 411 O S D 01323456
Table 2. Explanation of the PIN

Digit Description
1 to 3 World manufacturer identification. For example, JCB = UK Build.
4 to 6 Machine type and model
7 O = HT loader end
8 Designation: O = Non-Farmmaster, S = Farmmaster, I = India
9 Random check letter. The check letter is used to verify the authenticity of a machine's PIN.
10 to 17 Machine serial number
Engine
The engine data labels are attached to the cylinder block as shown.
10 9831/1850-4 10
About the Product
Figure 6.
B
A C
C
A Engine data label - rocker cover B Engine identification number
C Stamp
The data label includes the engine identification number.
Table 3. Example of the engine identification number

SJ 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 4.
Digit 1-2 Engine Type
SJ 4.4 L turbocharged and aftercooled electronic common rail fuel injection (Tier
4F)
DJ 4.8 L turbocharged and aftercooled electronic common rail fuel injection (Tier
4F)
Table 5. Explanation of the engine identification number

Digit Explanation
3-10 Engine part number
11 Country of manufacture. U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture
The country of manufacturer, engine serial number and year of manufacture of the engine are also stamped
on the crankcase. Refer to Figure 6.
Operator Protective Structure

ROPS and FOPS Data Plate
WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing
ROPS/FOPS/FOGS. If the ROPS/FOPS/FOGS has been in an accident, do not use the machine until the
structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS/FOPS/FOGS certification.
WARNING Do not use the machine if the falling objects protection level provided by the structure is not
sufficient for the application. Falling objects can cause serious injury.
WARNING Machines with a ROPS, FOPS,FOGS or TOPS are equipped with a seat belt. The ROPS,
FOPS,FOGS or TOPS is designed to give you protection in an accident. If you do not wear the seat belt you
11 9831/1850-4 11
About the Product
could be thrown off the machine and crushed. You must wear a seat belt when using the machine. Fasten
the seat belt before starting the engine.
A machine built to the ROPS (Roll-Over Protective Structure)/FOPS (Falling Object Protective Structure)
standard has a data plate attached to the inside of the cab.
Figure 7.
If the machine is used in any application where there is a risk of falling objects then a FOPS must be installed.
For further information, contact your JCB dealer.
The FOPS has a data plate attached. The data plate indicates what level protection the structure provides.
There are two levels of FOPS:
• Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small
concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and
other construction site services.
• Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for
machines involved in site clearing, overhead demolition or forestry.
12 9831/1850-4 12
About the Product
Safety Labels
Safety Labels
General
WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not
obey the safety instructions shown.
The safety labels are strategically placed around the machine to remind you of possible hazards.
If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-
stretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard
shown on the safety label, then refer to Safety Label Identification.
Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the
replacement parts include the safety labels where necessary. Each safety label has a part number printed on
it, use this number to order a new safety label from your JCB dealer.
Safety Label Identification
13 9831/1850-4 13
About the Product
Safety Labels
Figure 8.
N
332/ P7128- 1
332/P7181-1
332/P4679
C
332/P7134-1
332/P4581
D
817/70024-2
817/70004
817/70012-2
K H G
E
332/W6368
817/70014-3
J
F
817/70029-3
817/70008
Table 6. Safety Labels

Item Part No. Description Qty.
A 332/P7128 Burns to fingers and hands. Stay a safe distance away. 1
B 332/P4679 Warning. Severing of hands and fingers. Keep clear of/do not reach into 2
rotating parts. Read the Service Manual.
C 332/P4581 Warning. Severing of hands and fingers. Keep clear of/do not reach into 1
rotating parts.
D 817/70004 Warning. Burns to fingers and hands. Stay a safe distance away. 1
E 332/W6368 Strike. Keep clear of the reversing machine. 1
F 817/70008 Crushing of whole body. Keep a safe distance from machine. 2
G 817/70012 Run over hazard. Start the engine from the operator's seat only. Do not 1
short across the terminals.
14 9831/1850-4 14
About the Product
Safety Labels
Item Part No. Description Qty.

H 332/F5855 Warning. Pressure hazard. Read the Operator’s Manual. 1
J 817/70029 Warning. Crush hazard. Wear seat belt. 1
K 817/70014 Warning. Read the Operator’s Manual before you operate the machine. 1
L 817/70024 Warning. Do not use as a step. 1
M 332/P7134 Entanglement hazard. Do not touch. 1
N 332/P7181 Crushing of whole body. Attach/use the support or prop to lockout for 1
service, maintenance or any access.
15 9831/1850-4 15
About the Product
Operator Station
Operator Station
Component Locations
Figure 9.
B C D E F
A G
K H
Z L
X
N
Q R
P
W
S
AA
T
M
V U
Y
A Transmission Refer to: Drive Controls B Steering wheel Refer to: Steering Wheel
(Page 60). (Page 65).
C Front display panel Refer to: Instruments D Multi purpose steering column switch Refer to:
(Page 70). Multi-Purpose Switch (Page 17).
E Console switches Refer to: Console Switches F ATC (Automatic Temperature Control) panel or
(Page 20). optional manual HVAC (Heating Ventilation Air
Conditioning) controls Refer to: Air-Conditioning
Controls (Page 92).
G Radio H Secondary display panel (option) Refer to:
Instruments (Page 70).
J Proportional lever controls Refer to: Operating K Rotary switch panel Refer to: Instruments
Levers/Pedals (Page 82). (Page 70).
L Park brake switch Refer to: Park Brake M Park brake lever Refer to: Park Brake
(Page 67). (Page 67).
N Starter switch Refer to: Ignition Switch P Forward reverse switch Refer to: Forward,
(Page 17). Neutral and Reverse Switch (Page 66).
Q Multi lever controls Refer to: Drive Controls R Primary auxiliary controller (option)Refer to:
(Page 60). Auxiliary Circuit Controls (Page 83).
S Secondary auxiliary controller (option) T Transmission disconnect
U Horn V Transmission kickdown switch Refer to:
Transmission Kickdown Switch (Page 68).
W Armrest Refer to: Armrest (Page 40). X Accelerator pedal Refer to: Accelerator Pedal
(Page 65).
Y Seat Refer to: Operator Seat (Page 37). Z Service brake pedal Refer to: Service Brake
Pedal (Page 67).
16 9831/1850-4 16
About the Product
Interior Switches
Interior Switches
Ignition Switch
The ignition key operates the 4-position ignition switch. The ignition key can only be inserted or removed in
position O.
If the engine fails to start, the ignition key must be returned to position O before the starter motor is re-engaged.
Do not operate the starter motor for more than 10 s without the engine firing. If the engine fires but does not fully
start, do not operate the starter for more than 40 s. Let the starter motor cool for at least 2 min between starts.
Table 7. Switch positions

Function
O Turn the ignition key to this position to stop the engine. Make sure the transmission is in neutral, the
attachments are lowered and the park brake is engaged before you stop the engine
I Turn the ignition key to this position to connect the battery to all of the electrical circuits (except the
lights and hazard warning lights which are permanently live). The ignition key will return to this posi-
tion when it is released from position II or III
II This position is not used
III Turn the ignition key to this position to operate the starter motor which turns the engine. (Only when
the transmission is in neutral)
Figure 10.
O
I
II
III
Multi-Purpose Switch
Direction Indicators
Push the stalk forwards to indicate a left turn. Pull the stalk backwards to indicate a right turn. Place in central
position to cancel.
Windscreen Wiper
Rotate the switch barrel to activate and cancel the windscreen wipers. The wiper speed can vary dependant
on machine specification.
Single Speed (Standard)

0 = Off
I = On
Two Speed (Optional)

J = Intermittent wipe
17 9831/1850-4 17
About the Product
Interior Switches
0 = Off
I = Slow
II = Fast
Windscreen Washer
Push the button to activate the windscreen washer. Allow the stalk to spring back to central position when
finished.
Horn
Push the button to activate the horn. Allow the stalk to spring back to central position when finished.
Headlights Flash
Lift the stalk upwards to flash the headlights. Allow the stalk to spring back to central position when finished.
Main Beam
When the road lights are switched on via main switch on console, push the stalk downwards to turn on the
main beam. Pull the stalk upwards to the central position to turn off main beam.
Figure 11.
B
E
D
F
A
A Backwards - Right turn B Forwards - Left turn
C Rotate - Wiper on and off D Horn
E Upwards - Headlights flash F Downwards - Main beam
G Windscreen washer
Cab Interior Light
Three position switch. Make sure the cab interior light is turned off when you intend to leave the machine for
a long period of time.
Position : 1 = Interior light and ambient light off
Position : 2 = Interior light operates when cab door open, ambient light comes on when side lights switched on
Position : 3 = Interior light comes on permanently
18 9831/1850-4 18
About the Product
Interior Switches
Figure 12.
A B
A Cab interior light B Switch
19 9831/1850-4 19
About the Product
Console Switches
Console Switches
General
The console switches may change according to machine specifications. Some are used as options.
Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure
that you understand its function.
The push button switches symbol lights up to show that the switch function is active. If there are more than one
option active two lights are shown by the two red LED (Light Emitting Diode)'s.
Figure 13.
1 2
3 4
5 6
7 8
13 14
9 10
15 16
11 12
17 18
28
19 20
27
21 22 26
23 24 25
The indicator lamp on the button will illuminate to indicate that the switches are on in position.
1. Road light switch: The switch functions operate when the ignition switch is in the off position. The button
turns on the machine's front and rear side lights. A second press will turn off the side lights along with the
headlamps and worklamps.
2. Headlight switch: The switch function operate when the side lights are on and the ignition switch is in the on
position. The button turns on the machine's front headlamps. A second press will turn the headlamps off.
3. Beacon switch: The switch functions operate when the ignition switch is in the off position. The button turns
on the machine's roof-mounted rotating beacon. A second press will turn the beacon off.
20 9831/1850-4 20
About the Product
Console Switches
4. Rear fog light switch: The switch function operate when the headlamps are on in position. The button turns
on the machine's high-intensity read fog lamp. A second press will turn the fog lamp off.
5. Front work lamps switch: The button turns on the machine's high-intensity front work lamps. If additional
front work lamps are installed a second press will turn these on. A subsequent press will turn off all front
work lamps.
5.1. The indicator lamps on the button will illuminate to indicate that the first and second sets of lamps
are on.
6. Rear work lamps: The switch function operate when the road lights are turned on. The button turns on the
machine's high-intensity rear work lamps. If additional rear work lamps are installed a second press will
turn these on. A subsequent press will turn off all front work lamps.
6.1. The indicator lamps on the button will illuminate to indicate that the first and second sets of lamps
are on.
7. Rear wash/wipe switch: The button turns on the rear wiper. A second press will turn off the wiper. Pressing
and holding the button will wash and wipe the window.
8. Heated rear screen switch: The button turns on the heated rear screen and heated mirrors if installed. The
output will turn off automatically after few minutes as specified or if the button is pressed for a second time.
Duration: 10 min
9. Secondary steering switch: The button operates the electric backup steering system when the machine is
not moving. Use this function to test that the system can successfully pressurise the machine's steering
circuit. When pressure is detected in this circuit the secondary steer indicator lamp on the dashboard will
illuminate.
10. Engine mode switch (if installed): The button cycles through the available engine operating modes. Use this
function to increase efficiency by using the most appropriate mode for the current machine duty. Available
modes are normal for increased fuel economy and power for maximum performance.
10.1. The indicator lamp on the button will illuminate to show the power mode has been selected. Normal
mode is selected when the lamp is off.
11. Transmission auto mode switch: The button turns on the transmission auto shift mode. With auto mode
turned on the machine will select the most appropriate gear automatically to improve driveability and
efficiency.
12. Hydraulic tow hitch (option): The button controls the operation of the hydraulic operated tow hitch. Deploy/
retract and lift/lower functions are enabled through this button.
13. Not Applicable
14. Not Applicable
15. Transmission disconnect switch: The button turns on the brake activated transmission disconnect function.
With this function turned on the machine will intelligently stop drive from the transmission when the brakes
are pressed increasing efficiency of the machine and diverting all available power to the hydraulics.
16. Constant flow switch: This switch turns on the constant flow function available on both auxiliary services.
Constant flow allows the auxiliary hydraulics to be operated without the need for keeping a hand on the
control lever. This is particularly useful when operating attachments for long periods of time. To enable
constant flow press the switch. One light will illuminate to indicate that constant flow has been enabled.
Constant flow will be active on all auxiliary services. Push and hold the required auxiliary roller/lever fully
in the appropriate direction for greater than 2 seconds to start auxiliary flow. The roller/lever can now be
released and the auxiliary service selected will continue to operate at maximum flow. The system will
continue to operate until either; the constant flow switch is pressed (the light will turn off) or the roller/lever
is operated in the opposite direction or the hydraulic system is isolated.
16.1. Variable-Constant Flow - (Secondary display only - option) To adjust the flow rates on each auxiliary
service navigate to the constant flow menu on the secondary display. First and second auxiliary flow
rates can be adjusted independently through this menu.
21 9831/1850-4 21
About the Product
Console Switches
17. Fan reverse switch (option): The button manually activates the engine fan reversal. When this button is
pressed and held, the fan slows from normal direction then changes to reverse direction whilst the button
is held.
18. SRS (Smooth Ride System) switch: The button turns on the automatic SRS. Smooth ride mode provides
more comfort to the operator when travelling on an uneven surface and will activate automatically above
a set speed. A second press will turn off the SRS.
19. Detents switch: The button turns on the loader controller detent functions. The detents hold the loader
control in operation until the arms / shovel reach the return to dig, float and boom kick out positions. A
second press will turn off the function.
20. SCR (Selective Catalytic Reduction) stationary refresh switch: The button initiates cleaning of the
aftertreatment system. This may be used by the operator to begin a cleaning cycle when prompted.
21. SCR refresh inhibit switch: The button prevents the automatic cleaning of the aftertreatment system. This
may be used by the operator to prevent high exhaust temperatures that can occur during the cleaning cycle.
22. Precession hydraulic mode/auxiliary venting switch: The switch cycles through the available hydraulic
operating modes.
22.1. Precession hydraulic mode (Multi Lever Controls only): Use this function to improve precision by
using the most appropriate mode for the current machine duty. Available modes are normal for
maximum speed and precision for half speed.
22.2. The left indicator lamp on the switch will illuminate to show that precision mode has been selected.
Normal mode is selected when the left lamp is off.
22.3. Auxilary dump function (if fitted): This mode enables the operator to dump auxiliary circuit by diverting
hydraulic oil back to the hydraulic tank.
Refer to: Auxiliary Circuit Controls (Page 83).
23. Quickhitch disconnect switch: The button diverts auxiliary hydraulic flow to the quickhitch carriage locking
pins. Use this function to conveniently disconnect and reconnect attachments without leaving the cab.
24. Hydraulic lock switch: The button isolates or enables all of the machine loader end hydraulics. Use this
function to prevent inadvertent operation of the loader end. The hydraulic lock switch will default to the last
setting on each start up of the machine.
25. Mirror switch.
26. Park brake switch (option).
Refer to: Park Brake (Page 67).
27. Actuator hazard switch.
28. Rotary switch.
Refer to: Instrument Panel (Page 70).
22 9831/1850-4 22
Operation
Introduction
Operation
Introduction
General
The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to
operate the machine efficiently and safely. Read the Operation section through from beginning to end.
The operator must always be aware of events happening in or around the machine. Safety must always be the
most important factor when you operate the machine.
When you understand the operating controls, gauges and switches, practice using them. Drive the machine in
an open space, clear of people. Get to know the 'feel' of the machine and its driving controls.
Do not rush the job of learning, make sure you fully understand everything in the Operation section. Take your
time and work efficiently and safely.
Remember:
• Be careful.
• Be alert.
• Be safe.
23 9831/1850-4 23
Operation
Operating Safety
Operating Safety
General
Training
Make sure that you have had adequate training and that you are confident in your ability to operate the machine
safely before you use it. Practice using the machine and its attachments until you are completely familiar with
the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe
and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life,
or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your colleagues
what you will be doing and where you will be working. On a busy site, use a signalman.
Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will
be glad to advise you.
Fuel
Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is
suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running.
Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow
these precautions.
Machine Condition
A defective machine can injure you or others. Do not operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this manual are completed before using the machine.
Machine Limits
Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do
not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved
modifications or additional equipment.
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the
fault has been corrected.
Exhaust Gases
Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled. Do not operate the
machine in closed spaces without making sure there is good ventilation. If possible, install an exhaust extractor.
If you begin to feel drowsy, stop the machine at once and get into fresh air.
Worksites
Worksites can be hazardous. Examine the site before working on it. You could be killed or injured if the ground
gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs,
ironwork etc. Any of these could cause you to lose control of your machine. Check for utilities such as electric
cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables
and pipes. Make sure that you have enough clearance beneath overhead cables and structures.
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you
will be working with other people, make sure any hand signals that may be used are understood by everybody.
Worksites can be noisy, do not rely on spoken commands.
Parking
An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual
to park the machine correctly.
Banks and Trenches
Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there
is danger of collapse.
Safety Barriers
Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced,
place barriers around the work area to keep people away.
24 9831/1850-4 24
Operation
Operating Safety
Sparks
Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine
in closed areas where there is flammable material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out door atmospheric conditions. It must not be used in an
enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e.
combustible vapours, gas or dust, without first consulting your JCB dealer.
Regulations
Obey all laws, worksite and local regulations which affect you and your machine.
Electrical Power Cables
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical
power cables.
You are strongly advised to make sure that the safety arrangements on site comply with the local laws and
regulations concerning work near electric power lines.
Before you start using the machine, check with your electricity supplier if there are any buried power cables
on the site.
There is a minimum clearance required for working beneath overhead power cables. You must obtain details
from your local electricity supplier.
Working Platform
Using the machine as a working platform is hazardous. You can fall off and be killed or injured. Never use the
machine as a working platform unless with approved man-basket or man-crate (if applicable).
Machine Safety
Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair
before resuming work.
Hot Components
Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been
running. Allow the engine and components to cool before servicing the unit.
Travelling at High Speeds
Travelling at high speeds can cause accidents. Always travel at a safe speed to suit working conditions.
Hillsides
Operating the machine on hillsides can be dangerous if the correct precautions are not taken. Ground conditions
can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low
to the ground.
Visibility
Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights,
windows, mirrors and cameras clean (when fitted).
Do not operate the machine if you cannot see clearly.
Modification of the machine's configuration by the user (e.g. the fitting of large and non-approved attachments)
may result in a restriction of the machine visibility.
Hands and Feet
Keep your hands and feet inside the machine.
When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within
the operator compartment while the vehicle is in motion.
Controls
You or others can be killed or seriously injured if you operate the control levers from outside the machine.
Operate the control levers only when you are correctly seated.
25 9831/1850-4 25
Operation
Operating Safety
Passengers
Passengers in or on the machine can cause accidents. Do not carry passengers.
Fires
If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.
Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as
possible.
Roll Over Protection
If the machine starts to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll
over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.
Confined Areas
Pay extra attention to proximity hazards when operating in confined areas. Proximity hazards include buildings,
traffic and bystanders.
Safe Working Loads
Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual
before using the machine.
Lightning
If you are inside the machine during a lightning storm stay in the machine until the storm has passed. If you
are outside of the machine during a lightning storm stay away from the machine until the storm has passed.
Do not attempt to mount or enter the machine.
If the machine is struck by lightning do not use the machine until it has been checked for damage and
malfunction by trained personnel.
Worksite Safety
WARNING You or others can be killed or seriously injured if you do unfamiliar operations without first
practising them. Practise away from the worksite on a clear area. Keep other people away. Do not perform
new operations until you are sure you can do them safely.
WARNING There could be dangerous materials such as asbestos, poisonous chemicals or other harmful
substances buried on the site. If you uncover any containers or you see any signs of toxic waste, stop the
machine and advise the site manager immediately.
WARNING Before you start using the machine, check with your local gas company if there are any buried
gas pipes on the site.
If there are buried gas pipes we recommend that you ask the gas company for any specific advice regarding
the way you must work on the site.
Some modern gas pipes cannot be detected by metal detectors, so it is essential that an accurate map of
buried gas pipes is obtained before any excavation work commences.
Hand dig trial holes to obtain precise pipe locations. Any cast iron pipes found must 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, make sure that all naked lights are extinguished and switch off any engines which may be
running.
regulations concerning work near buried gas pipes.
CAUTION Before you start using the machine, check with your local public water supplier if there are buried
pipes and drains on the site. If there are, obtain a map of their locations and follow the advice given by
the water supplier.
26 9831/1850-4 26
Operation
Operating Safety
regulations concerning work near buried pipes and drains.
CAUTION If you cut through a fibre optic cable, Do not look into the end of it, your eyes could be permanently
damaged.
An applicable worksite organisation is required in order to minimise hazards that are caused by restricted
visibility. The worksite organisation is a collection of rules and procedures that coordinates the machines and
people that work together in the same area. Examples of worksite organisation include:
• Restricted areas
• Controlled patterns of machine movement
• A system of communication.
You and/or your company could be legally liable for any damage you may cause to public utilities. It is your
responsibility to make sure that you know the locations of any public utility cables or pipes on the worksite
which could be damaged by your machine.
Risk Assessment
It is the responsibility of the competent people that plan the work and operate the machine to make a judgement
about the safe use of the machine, they must take into account the specific application and conditions of use
at the time.
It is essential that a risk assessment of the work to be done is completed and that the operator obeys any
safety precautions that the assessment identifies.
If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be
pleased to advise you.
The following considerations are intended as suggestions of some of the factors to be taken into account when
a risk assessment is made. Other factors may need to be considered.
A good risk assessment depends on the training and experience of the operator. Do not put your life or the
lives of others at risk.
Personnel
• Are all persons who will take part in the operation sufficiently trained, experienced and competent? Are
they fit and sufficiently rested? A sick or tired operator is a dangerous operator.
• Is supervision needed? Is the supervisor sufficiently trained and experienced?
• As well as the machine operator, are any assistants or lookouts needed?
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and in good condition and is there sufficient fuel to complete
the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of the machine?
• How bulky is it? The greater the surface area, the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight distributed? Uneven loads are more difficult to handle.
• Is there a possibility of the load shifting while being moved?
Loading/Unloading Area
• Is it level? Any slope of more than 2.5% (1 in 40) must be carefully considered.
27 9831/1850-4 27
Operation
Operating Safety
• Is more than one direction of approach to the load possible? Approaching across the slope must be
avoided, if possible.
• Is the ground solid? Will it support the weight of the machine when loaded?
• How rough is the ground? Are there any sharp projections which could cause damage, particularly to
the tyres?
• Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power
lines?
• Is the space sufficient for safe manoeuvring?
• Are any other machines or persons likely to be in or to enter the area while operations are in progress?
The Route to be Travelled

• How solid is the ground, will it provide sufficient traction and braking? Soft ground will affect the stability
of the machine and this must be taken into account.
• How steep are any slopes, up/down/across? A cross slope is particularly hazardous, is it possible to detour
to avoid them?
Weather
• How windy is it? High wind will adversely affect the stability of a loaded machine, particularly if the load
is bulky.
• Is it raining or is rain likely? The ground that was solid and smooth when dry will become uneven and
slippery when wet, and it will not give the same conditions for traction, steering or braking.
28 9831/1850-4 28
Operation
General
WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the
attachments or get caught in the linkages. Lower the attachments to the ground before doing these checks.
Also make sure that the park brake is engaged before doing these checks.
The following checks must be made each time you return to the machine after leaving it for any period of time.
We advise you also to stop the machine occasionally during long work sessions and do the checks again.
All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer
to check and correct any defects.
1. Check for cleanliness.

1.1. Clean the windows, light lenses and the rear view mirrors (where applicable).
1.2. Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator.
1.3. Make sure the cab step and handrails are clean and dry.
1.4. Clean all of the safety and instructional labels. Replace any label that is missing or cannot be read.
2. Check for damage.
2.1. Examine the machine generally for damaged and missing parts.
2.2. Make sure that the attachment is correctly attached and in good condition.
2.3. Make sure that all of the pivot pins are correctly installed.
2.4. Examine the windows for cracks and damage. Glass splinters can blind.
2.5. Check for oil, fuel and coolant leakages below the machine.
WARNING! You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged,
incorrectly inflated or excessively worn tyres.
3. Check the tyres.

Refer to: Tyres (Page 184).
4. Make sure that all of the filler caps are installed correctly.
5. Make sure that all of the access panels are closed correctly.
Refer to: Access Apertures (Page 150).
6. If the filler caps and access panels are installed with locks, we recommend that you lock them to prevent
theft or tampering.
29 9831/1850-4 29
Operation

General
CAUTION Entering or leaving the operator station must only be made where steps and handrails are
provided. Always face the machine when entering and leaving. Make sure the steps, handrails and your
boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds,
only use the handrails.
Make sure the machine is stopped and correctly parked before entering or leaving the cab. Refer to: Stopping
and Parking (Page 52).
When you get on and off the machine always maintain a three point contact with the handrails and step. Do
not use the machine controls or steering wheel as handholds.
The illustration shows a typical machine model, your machine may look different from the model shown. Refer
to Figure 14.
Figure 14.
C
A Left handrail B Right handrail
C Step(s)
Emergency Exit
In an emergency if the door cannot be used, a sliding window with toughened glass can be removed with the
glazing breaker located to the right side of the cab.
The emergency exit window has a label attached in the position as shown.
30 9831/1850-4 30
Operation
Figure 15.
A
B
A Emergency exit label B Sliding window handle
Glazing Breaker
If the machine has a glazing breaker, it is possible to use the side window as an emergency exit.
If an emergency occurs:
1. Remove the glazing breaker from its stowage position.

2. Use the glazing breaker to hit the side window near the corner to shatter the side window.
3. Knock the side window out of its frame.
Figure 16.
A Glazing breaker
31 9831/1850-4 31
Operation
Doors
Doors
Operator Door
CAUTION Do not drive the machine with the door unlatched. It must be correctly closed or secured fully
open.
To open the door from the outside, unlock it with the ignition key and press the lock barrel to release the latch.
Pull the handle towards you.
Figure 17.
A Door B Lock barrel
To open the door from inside, pull the lever upwards.
Close the door from the inside by pulling the handle towards you, it will latch itself.
Figure 18.
A Lever B Handle
The buzzer will sound when the door is open and the park brake is off.
32 9831/1850-4 32
Operation
Windows
Windows
Side Window
The side window is held closed by a latch operated from inside the cab.
To open the window, operate the latch and slide the window to the desired position.
To close the window, slide the window fully shut and check that the latch has located on the frame.
Figure 19.
A B
A Latch B Frame
33 9831/1850-4 33
Operation
Battery Isolator
Battery Isolator
General
Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect
the circuits and components. The battery must still be disconnected even if a battery isolator is installed.
Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the
machine electrics.
To allow the engine ECU (Electronic Control Unit) to shut down correctly, you must wait 60 s before you isolate
the battery. The 60 s period starts when you turn the ignition off.
Disconnect the Machine Electrics:

1. Turn the ignition key to the off position.
2. Wait for the engine ECU to shutdown correctly.
Duration: 60 s
3. Get access to the battery isolator.
Refer to: Service Points (Page 148).
4. Turn the battery isolator key in a counter-clockwise direction and remove.
Connect the Machine Electrics:

1. Make sure the ignition is switched off.
2. Insert the battery isolator key and turn in a clockwise direction.
34 9831/1850-4 34
Operation

General
DANGER Before lowering the attachments to the ground, make sure that the machine and the area around
it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments,
or get caught in the linkages.
WARNING Secure all loose articles. Loose articles can fall and strike you or roll on the floor. You could
be knocked unconscious, or the controls could get jammed. If that happens you could lose control of the
machine.
CAUTION Machines installed with hose burst protection valves cannot have their attachments lowered with
the engine stopped. Start the engine and lower the attachments before doing the walk-around inspection.
1. The park brake should have been engaged when the machine was last parked. If it is not already set to
on, set it to on now.
2. Read the Operating in Low Temperatures or Operating in High Temperatures procedures in the Operation
section if you will be using the machine in very cold or very hot climates.
Refer to: Operating Environment (Page 105).
3. If the fuel tank was empty or if any part of the fuel system has been drained or disconnected, the fuel system
must be primed before you try to start the engine.
4. If necessary, lower the attachment to the ground. They will lower themselves under their own weight when
you operate the controls. Operate the controls carefully to control the rate of descent.
Refer to: Operating Levers/Pedals (Page 82).
5. For your own safety (and others) and for the maximum service life of your machine, do a pre-start inspection
before you start the engine.
5.1. If you have not done it, do a walk-around inspection of the outside of the machine.
Refer to: Walk-Around Inspection (Page 29).
5.2. Do the daily checks.
Refer to: Pre-start Cold Checks, Service Points and Fluid Levels (Page 141).
5.3. Remove any dirt and rubbish from the cab interior, specially around the pedals and control levers.
5.4. Remove any oil, grease and mud from the pedals and control levers.
5.5. Make sure that your hands and shoes are clean and dry.
5.6. Remove or stow all loose articles in the cab, for example tools.
5.7. Examine the ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure)
for damage. Get your JCB dealer to repair any damage. Make sure all its securing bolts are installed
and correctly tightened.
Refer to: Check (Condition) (Page 159).
5.8. Examine the cab for loose or missing bolts, screws etc. Replace or tighten where necessary.
5.9. Examine the seat belt and its mountings for damage and excessive wear.
5.10. Operate the lights, horn, all switches, front window washer and wipers (if installed).
Refer to: Electrical System (Page 189).
6. If necessary, adjust the seat so that you can comfortably reach all the driving controls. You must be able
to fully push the brake pedal with your back against the seat back.
Refer to: Operator Seat (Page 37).
7. If necessary, adjust the steering column so that you can reach the steering wheel and the steering column
switches without stretching.
Refer to: Steering Column (Page 65).
35 9831/1850-4 35
Operation
8. Adjust the rear view mirrors (if applicable) to give you a good view close behind the machine, when you
are correctly seated.
Refer to: Mirrors (Page 44).
9. Fasten the seat belt.
36 9831/1850-4 36
Operation
Operator Seat
Operator Seat
General
CAUTION Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat
while the machine is moving. You could have an accident if you operate the machine with the seat in the
wrong position.
The operator's seat can be adjusted for your comfort. A correctly adjusted seat will decrease the operator
fatigue.
Adjust the seat so that you can comfortably reach the machine controls.
For driving the machine, adjust the seat so that you can push the pedals fully down when your back is against
the seat back.
Basic Seat
Figure 20.
A D
C
A Fore/Aft adjustment B Height adjustment
C Ride height indicator D Backrest angle adjustment
37 9831/1850-4 37
Operation
Operator Seat
Standard Seat
Figure 21.
A G
B
C
D
E
A Fore/Aft adjustment B Seat cushion tilt adjustment
C Seat cushion depth adjustment D Height adjustment
E Ride height indicator F Backrest angle adjustment
G Left armrest adjustment
38 9831/1850-4 38
Operation
Operator Seat
Delux Seat
Figure 22.
G
A
B
C
D E F
A Seat cushion tilt adjustment B Seat cushion depth adjustment
C Height adjustment D One touch riser
E Ride height indicator F Fore/Aft adjustment and isolator
G Backrest angle adjustment H Heater
39 9831/1850-4 39
Operation
Operator Seat
Super Delux Seat

Figure 23.
A
B H
C
G
D
F
E
A Seat cushion tilt adjustment B Seat cushion depth adjustment
C Damper adjustment D Height adjustment
E One touch riser F Ride height indicator
G Fore/Aft adjustment and isolator H Backrest angle adjustment
J Heater/Active cooling
Armrest
The position of the armrest can be adjusted to give the operator a comfortable and supportive position to move
the loader controls.
Press the armrest button to unlock and adjust the armrest height.
40 9831/1850-4 40
Operation
Operator Seat
Figure 24.
A Armrest button
41 9831/1850-4 41
Operation
Seat Belt
Seat Belt
General
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.
WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the
fabric is worn, or if the machine has been in an accident.
Inertia Reel Seat Belt
Fasten the Seat Belt

WARNING If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of
the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before
starting the engine.
1. Sit correctly in the seat.

2. Pull the seat belt and the tongue from the inertia reel holder in one continuous movement.
3. Push the tongue into the latch. Make sure the seat belt is not twisted and that it is over your hips not your
stomach.
3.1. If the seat belt 'locks' before the tongue is engaged, let the seat belt retract into the inertia reel holder
then try again. The inertia mechanism can lock if you pull the seat belt too quickly or if the machine
is parked on an slope.
Figure 25.
A Tongue B Latch
WARNING! If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not
drive the machine. Get the seat belt repaired or replaced immediately.
4. To make sure the seat belt operates correctly, hold the middle of the seat belt and pull. The seat belt should
'lock'. Refer to Figure 26.
42 9831/1850-4 42
Operation
Seat Belt
Figure 26.
C Seat belt D Button
Release the Seat Belt

WARNING Release the seat belt only after safely stopping the machine, switching off the engine and
engaging the park brake (if applicable).
1. Push the button and pull the tongue from the latch.
2. Carefully let the seat belt retract into the inertia reel holder.
43 9831/1850-4 43
Operation
Mirrors
Mirrors
General
Introduction
WARNING Before reversing, make sure the area behind the machine is clear of other persons. If this is not
observed, injury or death can result.
When they operate the machine, the operator must continually survey their field of vision. It is important that
the mirrors are securely installed and give maximum vision around the machine.
When a mirror is provided to supplement the operators direct field of vision, it must be adjusted to serve as
an aid to the operator in seeing people or obstacles around the machine. The mirror provides indirect vision to
hidden areas and improves the effectiveness of the machines usage.
Do not operate the machine if the mirrors become damaged. Damage, personal injury or death can occur if
you do not have adequate visibility around the machine.
Make sure that when an attachment is installed it does not affect your area of visibility around the machine.
The illustration shows a typical machine model, your machine may look different from the model shown.
Figure 27.
B
A C
A Rear mirror B Rear view mirror

C Side mirror
44 9831/1850-4 44
Operation
Mirrors
Adjusting the Mirrors

1. Adjust the seat to suit the operator.
Refer to: Operator Seat (Page 37).
2. Adjust the mirror(s) to suit your specific working requirements before you drive or operate the machine.
3. Check the field of vision.
Checking the Field of Vision

Side Mirrors
You should be able to see with the mirrors a flat area on the left and right sides of the machine.
The field of vision shall be such that the operator can see, using the mirrors, at least a flat portion bounded on
the left and right of the machine, starting at the rear end of the machine at a height of 1 m above ground level
and a width of 0.75 m, continuing to a width of 3.5 m at ground level, 30 m behind the rear end of the machine.
Figure 28.
J
E
G F
B
G
H A C
A Field of vision B Centre point position
C Outer border D Inner border
E 1 m (height above the ground) F 0.75 m (width)
G 3.5 m (width) H Ground level
J 30 m (behind the machine)
45 9831/1850-4 45
Operation
Mirrors
Rear View Mirror

The field of vision at ground level shall be such that the operator can see, using the mirrors, at least a 10 m)
wide flat, horizontal portion of the ground, centred on the vertical longitudinal median plane of the machine,
30 m behind the rear end of the machine.
Figure 29.
E
A
A Field of vision B Centre point position
C Rear view mirror D 10 m (width)
E 30 m (behind the machine)
46 9831/1850-4 46
Operation
Mirrors
Rear Mirror
The field of vision at ground level shall be such that the operator can see, using the mirror, the area of ground
directly behind the machine.
Figure 30.
A Field of vision
47 9831/1850-4 47
Operation
Visual Aids
Visual Aids
Exterior View System
(Option)
The rear view on high specification display is designed to increase the operators visual area at the rear of
the machine.
• Camera system
• LCD (Liquid Crystal Display) monitor
• Radar object detection system (option)
The LCD is manufactured to show a 'reverse' image, so that the image seen by the operator is correct when
they reverse the machine. As the LCD cannot be changed from 'reverse' image, it cannot be used for other
purposes.
The radar detection system can operate in all weather conditions.
Operation
CAUTION Immediately after machine start-up the LCD monitor make take a short time to load and display
the camera image whilst the system initialises. Proper functioning is indicated by the presence of a clear
image on the LCD monitor.
When reversing the operator should use a combination of direct vision to area's around the machine and indirect
vision provided through mirrors and the rear-view system
If the rear-view system becomes damaged or defective it should be replaced without delay.
The camera system automatically powers-up and operates when the ignition key is set to the position I. Refer
to: Ignition Switch (Page 17).
The LCD and the camera operate continuously when the ignition key is in the position I.
Adjustments
The operator can not adjust the settings of the LCD, camera, sounder or the radar detector head. The system
is factory-set to give the optimal performance.
If the system is defective, contact your JCB dealer.
Radar Detection System (option)

The radar panel is situated in the cab below the ATC (Automatic Temperature Control) panel as shown.
48 9831/1850-4 48
Operation
Visual Aids
Figure 31.
A Radar
The camera system operates continuously when the ignition key is in the I position.
The radar detection system starts automatically when the reverse gear is selected.
The radar detection system stops when reverse gear is disengaged, but the camera system continues to
operate.
Detection Area (Zones)

The detection area has been divided into three zones.
The zone lengths of the three zones are specified on a sticker inside the vehicle.
Figure 32.
A B C
A Zone 1 (red illuminated) B Zone 2 (red flashing)

C Zone 3 (yellow flashing)
49 9831/1850-4 49
Operation
Visual Aids
Table 8. Signalling With Display

Distance to Ob- Indications on Display (if installed) Indication External Driver Actions
ject
(1)
Lights (if installed)
Over 4.5 m Visible: Green light Audible: No alarm Both lights off Driving at crawling
is on speed or slower
Zone 1: 4.5 –2.5 m Visible: Yellow light Audible: Interrupted Yellow light blinking Moving at a slower
blinking 2x per sec- 2x per second 2x per second speed than crawling
ond speed
Zone 1: 2.5 –1.5 m Visible: Red light Audible: Interrupted Red light blinking 4x Extremely slow
blinking 4x per sec- 4x per second per second speed, ready to
ond brake immediately
Zone 1: 1.5 –0 m Visible: Red light il- Audible: Uninterrupt- Red light constant Stop
luminated constantly ed sound
Detection unclear Visible: Alternately Audible: Dual sound Alternately blinking Stop and check area
blinking red and yel- red and yellow lights behind the vehicle
low lights
(1) Zone lengths depend on vehicle type and customer requirements
50 9831/1850-4 50
Operation
Starting the Engine
Starting the Engine

General
Notice: Do not use ether or other starting fluids to assist cold starting. Using these fluids may result in an
explosion causing possible injury and/or damage to the engine.
1. Make sure that the machine is ready to start.

Refer to: Before Starting the Engine (Page 35).
2. Put the forward/reverse lever in neutral.
Refer to: Driving the Machine (Page 81).
2.1. The engine will not start unless the forward/reverse lever is in neutral.
3. Make sure the park brake is set to on.
4. Make sure the battery isolator key is installed and switched on.
Refer to: Battery Isolator (Page 191).
5. Make sure you are sat in the seat
6. If the machine has an immobiliser then you must disarm the immobiliser before you can start the engine.
7. Turn the start key to position (I) to connect the battery to all of the electrical circuits.
8. For engine coolant temperatures below the figure specified for the use of a grid heater (if installed), the grid
heater light will illuminate. Wait for the grid heater light to extinguish.
Temperature: -4 °C ( 24.8 °F)
9. Turn the starter key further to position (II) and hold it there until the engine starts. Do not operate the starter
for more than the time specified.
Duration: 20 s
10. There is an intentional delay prior to starting the engine to ensure the engine lubrication system is primed.
The delay time is determined by the engine coolant temperature and can be up to:
Duration: 4 s
11. If the engine does not start, return the ignition key to the "0" position, Allow the starter to cool for the time
specified:
Duration: 2 min
12. After you start the machine there is an intentional delay at idle during which time the throttle control is
overridden to make sure that the lubrication system is primed. This is determined by the engine coolant
temperature. The delay time can be up to:
Duration: 28 s
13. If any warning lights fail to go off or come on while the engine is running, stop the engine as soon as it
is safe to do so.
Do not operate attachments until the hydraulic oil has reached its normal working temperature.
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 load).
The engine noise and / or tone may be louder than usual when the engine is cold. This is normal and is due
to the fuel injection timing being advanced. The engine will become quieter when the engine reaches normal
operating temperature.
51 9831/1850-4 51
Operation

General
Notice: The park brake must not be used to slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will be reduced.
1. Stop the machine on solid, level ground where the machine will not be a hazard or danger.
2. Slowly release the accelerator pedal and push down on the brake pedal to bring the machine to a smooth
stop.
2.1. Keep the foot brake applied until the park brake is applied and the drive disengaged.
3. Apply the park brake. Make sure that the park brake warning light comes on.
3.1. An audible alarm will sound and a warning light will come on when the park brake is applied with the
machine in forward or reverse drive. The alarm stops when neutral drive is selected.
3.2. If you leave the operators seat before setting the park brake to on, a warning buzzer will sound until
the park brake is set to on.
4. Release the foot brake.
5. Set the transmission to the neutral position. Make sure that the neutral lock is engaged.
DANGER! Before lowering the attachments to the ground, make sure that the machine and the area
around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
6. Operate the control lever to lower the attachment to the ground. Operate the controls a little further so that
the ground begins to support the weight.
6.1. Make sure that the attachment lies flat on the ground to prevent accidental movement.
7. Lock the controls.
8. It is recommended that turbo-charged engines are run at 1000 RPM (approximately) and at a reduced load
for few minutes to before shut down. This will let the turbo-charger cool.
Duration: 2 –3 min
9. Turn the ignition key to the O position to stop the engine.
10. Before you leave the machine, make sure that all switches are set to the off position. If necessary, leave
the hazard warning and/or side lights on.
11. Close and latch all the windows.
12. Remove the ignition key.
13. If necessary, lock the door.
CAUTION! Entering or leaving the operator station must only be made where steps and handrails are
provided. Always face the machine when entering and leaving. Make sure the steps, handrails and your
boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds,
only use the handrails.
14. Use the hand-holds and steps when you climb down from the machine.
15. At the end of a work cycle or if the machine is being left unattended isolate the machine.
Refer to: General (Page 148).
15.1. To allow the engine ECU (Electronic Control Unit) to shut down correctly, you must wait the duration
specified before you isolate the battery. The period starts when you turn the ignition off.
Duration: 60 s
52 9831/1850-4 52
Operation
53 9831/1850-4 53
Operation

General
When you travel on the road or on site there are usually local rules and safety regulations for the machine
travel position.
This publication contains recommendations that may help you meet the requirements of these regulations, they
are not necessarily the applied law.
If your machine is installed with a travel height label make sure you adhere to it.
Make sure that before you travel on public roads or site, you and your machine comply with all the relevant
local laws - it is your responsibility.
UK Road Travel
In the U.K. before you travel on the 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, follow the steps to take the vehicle on road:
Always assess your route for overhead structures such as bridges which could be damaged by your machine.
Use a restraint device to tie the bucket to the lower structure.
This information is believed to be correct, JCB cannot be aware of all circumstances in which JCB machines
may be operated on a public highway and it is the responsibility of the user to make sure the compliance with
the regulations.
Other Territories Road Travel

This publication does not contain the rules and laws of the areas that the machine will be travelling. Contact
your local authorities before you travel on public roads.
Preparing for Road Travel

JCB can not be aware of all circumstances in which JCB machines may be operated on a public road. Make
sure you will be obeying all the applicable laws and regulations before you take the machine on public roads.
Machines without headlights and side lights are for site use only. You may break local laws if you travel on the
road without headlights or side lights.
In certain countries (for example Italy) the legislation requires that the front windscreen guard (if installed) is
removed before you travel on public roads. Check the local legislation.
In the UK before you travel on public roads, it is your responsibility as a user to obey the Road Vehicles
(Construction and Use) (Amendment) Regulations 1997 ("Bridge Bashing Regulations."). As a guide only, the
following steps may be taken to comply with these regulations.
1. Always assess your route for overhead structures, for example bridges which could be damaged by your
machine.
2. Install the beacon. The traffic regulations may require you to operate the beacon when you travel on some
public roads.
Refer to: Beacon (Page 57).
3. If pivoting rear lights are fitted, complete this step (on both sides of the machine), otherwise continue to
the next step
3.1. Disengage the lockable hinge and pivot the light outwards (on both sides of the machine). Re-engage
the lockable hinge.
54 9831/1850-4 54
Operation
Figure 33.
A
C
A Lockable hinge B Rear light - inner position

C Rear light - outer position
4. Make sure that the road lights and the beacon operate correctly.
5. If towing, make sure that the towed equipment is attached correctly, this includes the electrics where
applicable.
6. Lower/raise the shovel to a position above the ground of approximately
Distance: 300 mm
Refer to: Lift Arm Controls (Page 82).
Figure 34.
B 300
A Tooth guard B Safety marker plate
7. Operate the controls to fully 'crowd' the shovel.

8. When you travel with a shovel, a tooth guard must be installed.
9. In certain countries the legislation requires that the safety marker plate is installed before you travel on
public roads. Check the local legislation.
10. If installed, start the SRS (Smooth Ride System).
Refer to: Smooth Ride System (SRS) (Page 56).
Preparing for Worksite Travel

1. If pivoting rear lights are installed, complete this step (on both sides of the machine), otherwise continue
to the next step.
1.1. Disengage the lockable hinge and pivot the rear light inwards (on both sides of the machine). Engage
the lockable hinge. Refer to Figure 35.
55 9831/1850-4 55
Operation
Figure 35.
C
A
A Rear light - outer position B Rear light - inner position

C Lockable hinge
2. Lower/raise the shovel to a position above the ground of approximately

Distance: 300 mm
3. Keep the shovel in this position when you:
3.1. Travel with a full shovel.
3.2. Reverse up a slope.
3.3. Travel across a slope.
4. If you drive or turn the machine with the lift arm in the raised position, the stability of the machine is
decreased
5. Operate the control to fully 'crowd' the shovel.
6. If installed, start the SRS (Smooth Ride System).
Refer to: Smooth Ride System (SRS) (Page 56).
Smooth Ride System (SRS)

The SRS (Smooth Ride System) (option) is a hydraulic suspension system which smooths the ride across
rough surfaces to improve the performance of the machine.
For all handling operations, the SRS system should be set to off.
The SRS supplies a "cushion" effect for the lift arm rams to give a smoother ride when you travel over rough
terrain. It is effective in all load conditions, from a full load to an empty shovel. The system enables faster travel
speeds and is ideal for moving loads over large distances.
The SRS is enabled by switching on the selector switch and activated automatically when the ground speed
reaches a set point.
The accumulators in the lift arms keep their charge at all times, so there is no possibility of a hydraulic collapse
when the SRS system is started.
When the SRS is engaged, the lift arm may lift or lower slightly, make sure all personnel are clear of the area.
To start the SRS:
1. Push and hold the SRS switch down.

Refer to: Console Switches (Page 20).
2. Adjust the position of the lift arm until it is 460 mm (18 in) above the ground.
56 9831/1850-4 56
Operation
3. The system will operate above a set point ground speed and the SRS warning light should illuminate on
the front console.
4. To disengage the SRS, turn off the SRS switch.
Beacon
We recommend that you install a beacon before you travel on public roads. In certain territories you will break
the law if you do not install a beacon before you travel on site/public roads, make sure you comply with the
local laws.
Be careful when you operate the machine with a beacon. The total height of the machine is increased when
the beacon is in the operating position.
A beacon kit is available as an option. The type of beacon is model dependant.
1. Make the machine safe.

2. If necessary, attach the beacon to the cab roof. (The beacon has a magnetic base).
3. Connect the plug from the beacon into the cab roof socket, as shown.
4. Push its switch on the right hand post to operate the beacon. The indicator light in the switch comes on
when the beacon is operating.
Figure 36.
A
A Beacon (s) B Plug (s)
Green Beacon (option)

The beacon will flash when the seat belt is on in position.
The beacon will be off when the seat belt is unfastened.
57 9831/1850-4 57
Operation
Safety Equipment
Safety Equipment
Articulation Lock
Transport Position
Make sure the articulation lock is in the transport position before you transport the machine. The articulation
lock must also be in the transport position when you do the daily checks or do any maintenance work in the
articulation danger zone. If the articulation lock is not in the transport position you could be crushed between
the two parts of the chassis.
The articulation lock is attached to the side of the machine. The articulation lock is installed with the machine
in the 'straight ahead' position.
1. Steer the machine to put the front and rear wheels in a straight line.
2. Engage the park brake, put the transmission in neutral and stop the engine and remove the starter key.
3. Remove the pins to release the articulation lock from its drive (stowage) position.
4. Place the articulation lock into the transport position, as shown.
5. Use the pins removed in step 3 to secure the articulation lock in the transport position, as shown. If the pins
do not fit, turn the steering wheel to align the holes in the chassis with the holes in the articulation lock.
When the pins are fitted, make sure that the pins are correctly secured with the correct locking devices to
prevent the articulation lock becoming insecure.
Figure 37.
A C B
A Pin B Pin
C Articulation lock
Drive (Stowage) Position

Always make sure the articulation lock has been removed from the transport position before you try to drive
the machine. The machine cannot be steered with the articulation lock in the transport position.
1. Make sure the park brake is engaged, the transmission is in neutral with the engine stopped. Remove the
starter key.
2. Remove the pins securing the articulation lock in the transport position.
3. Remove the articulation lock and position it into its stowage (drive) position.
4. Put the pins removed in step 2 in position to secure the articulation lock in the drive (stowage) position.
Make sure that the pins are correctly secured with the correct locking devices to prevent the articulation
lock becoming insecure.
58 9831/1850-4 58
Operation
Safety Equipment
Figure 38.
B
A Articulation lock B Pin
Control Lock
The control lock isolates the machines loader end hydraulic functions. Refer to: General (Page 20).
Figure 39.
The hydraulic controls must always be locked before the driver leaves the cab.
The lift arm controls must only be unlocked when the driver is correctly seated.
59 9831/1850-4 59
Operation
Drive Controls
Drive Controls
General
For: 411HT [T4F] ...................................................................................................................... Page 60
For: 413S [T4F] ........................................................................................................................ Page 61
For: 417HT [T4F] ...................................................................................................................... Page 63
(For: 411HT [T4F])
Transmission Modes
Introduction
To make sure that the most efficient gear ratio and shift points for a machine application are used, the operator
can select one of two transmission modes, Automatic or Manual.
Use the Automatic/Manual (A/M) switch to select a transmission mode suitable for the terrain and the work
that you will be doing.
Manual Mode: (A/M Switch is in the OFF position) Lets the operator manually select and hold 1st, 2nd or 3rd
gear.
Automatic Mode: (A/M Switch is in the ON position) Autoshifts from 1st to the gear selected on the barrel of
the transmission control lever.
If another range or direction is selected or either of the kickdown buttons are pressed, or the A/M switch is
changed the kickdown will be cancelled and 2nd gear will be selected.
Reverse only has 3 gears, (1st, 2nd and 3rd).
Operation
• Automatic mode starting gear is 2nd (forward and reverse).
• When the kickdown button is pressed, the downshift mode is active. When the kickdown button is pressed
once again, the downshift mode is cancelled. If the kickdown button is pressed again whilst still in the
same gear, downshift (Auto mode) is activated again and the transmission shifts down another gear.
• Downshift mode means that the current gear will be shifted down one gear. In Manual mode the new gear
will be locked. In Automatic mode the new gear is the new upper gear range limit.
• Downshift mode when enabled, inhibits selection of the current gear and the ones above Refer to Table 9.
• Downshift mode is cancelled under these conditions:
• Kickdown button pushed again.
• Gear range change (Barrel position).
• Direction change.
• Change between automatic mode and manual mode.
• Kickdown function is not road speed dependent. Maximum vehicle speeds for downshifting are
approximately (depending on tyre radius):
• 2nd to 1st forward: 12 km/h ( 7.5 mph), reverse 13 km/h ( 8.1 mph)
• 3rd to 2nd forward: 29 km/h ( 18.0 mph), reverse 30 km/h ( 18.6 mph)
• (4th to 3rd forward 66 km/h ( 41.0 mph))
Table 9. Automatic Mode - Typical Operation

Current Driving Condition Driver Action Resultant Driving Condition
(1)
(Gears Available)
4th gear selected. (Gears 1,2,3,4 Press kickdown button Downshift mode enabled. 4th gear
available) is inhibited and 3rd gear is se-
lected. (Gears 1, 2 and 3 only are
available)
3rd gear selected. (Gears 1, 2 and Driver reduces speed 2nd gear is selected automatical-
3 only are available) ly (Gears 1, 2 and 3 only are avail-
able)
60 9831/1850-4 60
Operation
Drive Controls

(1)
(Gears Available)
2nd gear selected. (Gears 1, 2 and Driver increases speed 3rd gear is selected automatical-
able)
3rd gear selected. (Gears 1, 2 and Driver increases speed further 3rd gear is held (Gears 1, 2 and 3
3 only are available) only are available)
3rd gear held. (Gears 1, 2 and 3 Press kickdown button Downshift mode disabled. 4th gear
only available) now becomes available and is se-
lected if suitable. (Gears 1, 2, 3
and 4 available)
(1) The actual gear selected from the available gear range in Auto mode will depend on speed / load conditions.
Table 10. Manual modes (Forward) (A/M switch is off)
Barrel position Gear range Kickdown available in gears
1 1st None
2 2nd 2nd
3 3rd None
4 Auto 2nd-3rd-4th 2nd
Table 11. Manual modes (Reverse) (A/M switch is off)

1 1st None
2 2nd 2nd
3 3rd None
4 Auto 2nd-3rd 2nd
Table 12. Automatic modes (Forward) (A/M switch is on)
1 1st None
2 Auto 1st-2nd 2nd
3 Auto 1st-2nd-3rd 2nd, 3rd
4 Auto 1st-2nd-3rd-4th 2nd, 3rd, 4th
Table 13. Automatic modes (Reverse) (A/M switch is on)
1 1st None
2 Auto 1st-2nd 2nd
(For: 413S [T4F])
Transmission Modes
Introduction
gear.
61 9831/1850-4 61
Operation
Drive Controls
If another range or direction is selected or either of the kickdown buttons are pressed or Auto / Manual is
changed, the kickdown will be cancelled and 2nd gear will be selected.
Operation
• Direction change (Except when locked in first gear).
• Change between automatic mode and manual mode (Except when locked in first gear).
• 2nd to 1st forward: 9 km/h ( 5.6 mph), reverse: 10 km/h ( 6.2 mph)
• 3rd to 2nd forward: 15 km/h ( 9.3 mph), reverse: 24 km/h ( 14.9 mph)
• 4th to 3rd forward: 22 km/h ( 13.7 mph)
• 5th to 4th forward: 35 km/h ( 21.7 mph)
• 6th to 5th forward: 52 km/h ( 32.3 mph)
• In gear selector position 2 to 1 and 1st gear engaged, pushing kickdown locks 1st gear.

(1)
(Gears Available)
4th gear selected. (Gears 1,2,3,4,5 Press kickdown button Downshift mode enabled. 4th, 5th
and 6 available) and 6th gear are inhibited and 3rd
gear is selected. (Gears 1, 2 and 3
only are available)
able)
able)
3rd gear held. (Gears 1, 2 and 3 Press kickdown button Downshift mode disabled. 4th,5th
only available) and 6th gear now become avail-
able and are selected if suitable.
(Gears 1, 2, 3, 4,5 and 6 available)
Table 15. Manual Modes (Forward) (A/M switch is off)

Barrel position Gear range Kickdown available in gears:
2 to 1 2nd 2nd
3 3rd 3rd
62 9831/1850-4 62
Operation
Drive Controls

4 4th 4th
A Auto 2nd-3rd-4th-5th-6th 2nd, 3rd, 4th, 5th, 6th
Table 16. Manual Modes (Reverse) (A/M switch is off)

2 to 1 2nd 2nd
3 2nd 2nd
4 3rd 3rd
A Auto 2nd-3rd 2nd, 3rd
Table 17. Automatic Modes (Forward) (A/M switch is on)

2 to 1 Auto1st-2nd 1st (Locking 1st gear), 2nd
A Auto 1st-2nd-3rd-4th-5th-6th 2nd, 3rd, 4th, 5th, 6th
Table 18. Automatic Modes (Reverse) (A/M switch is on)

2 to 1 Auto 1st-2nd 1st (Locking 1st gear), 2nd
3 Auto 1st-2nd 2nd
A Auto 1st-2nd-3rd 2nd, 3rd
(For: 417HT [T4F])
Transmission Modes
Introduction
gear.
If another range or direction is selected or either of the kickdown buttons are pressed, or the A/M switch is
changed the kickdown will be cancelled and 2nd gear will be selected.
Operation
63 9831/1850-4 63
Operation
Drive Controls
• Direction change.
• Change between automatic mode and manual mode.
• 2nd to 1st forward: 11 km/h ( 6.8 mph), reverse 12 km/h ( 7.5 mph)
• 3rd to 2nd forward: 27 km/h ( 16.8 mph), reverse 29 km/h ( 18.0 mph)
• (4th to 3rd forward 63 km/h ( 39.1 mph))

(1)
(Gears Available)
4th gear selected. (Gears 1,2,3,4 Press kickdown button Downshift mode enabled. 4th gear
available) is inhibited and 3rd gear is se-
lected. (Gears 1, 2 and 3 only are
available)
able)
able)
3rd gear held. (Gears 1, 2 and 3 Press kickdown button Downshift mode disabled. 4th gear
only available) now becomes available and is se-
lected if suitable. (Gears 1, 2, 3
and 4 available)
Table 20. Manual modes (Forward) (A/M switch is off)

1 1st None
2 2nd 2nd
3 3rd None
4 Auto 2nd-3rd-4th 2nd
Table 21. Manual modes (Reverse) (A/M switch is off)

1 1st None
2 2nd 2nd
3 3rd None
4 Auto 2nd-3rd 2nd
Table 22. Automatic modes (Forward) (A/M switch is on)

1 1st None
2 Auto 1st-2nd 2nd
64 9831/1850-4 64
Operation
Drive Controls

Table 23. Automatic modes (Reverse) (A/M switch is on)

1 1st None
2 Auto 1st-2nd 2nd
Steering Wheel
Turn the steering wheel in the direction you want to go. Refer to: Component Locations (Page 16).
The steering wheel incorporates an assister knob for single handed operation.
Steering Column
CAUTION Make sure the steering column is locked in position. Do not adjust the steering column while
driving.
Use the lever to set the steering column to the correct position for when you sit correctly on the operator seat.
1. Pull the lever up to unlock the steering column.

2. Adjust the steering wheel to the correct position (lift, lower, tilt forward/backward).
3. Push the lever down to lock the steering column in position.
4. Operate the park handle to lock the steering column.
Figure 40.
A
A Lever B Park handle
Accelerator Pedal
The accelerator pedal is located on the floor of the cab, to the right of the steering column.
65 9831/1850-4 65
Operation
Drive Controls
The travel speed is governed by depressing the accelerator pedal.
Release the pedal to decrease the travel speed. Refer to: Component Locations (Page 16).
Forward, Neutral and Reverse Switch
Do not operate the forward/reverse switch when already using the forward/reverse lever, otherwise the
transmission will select neutral. If this occurs, to engage drive again both controls need to be returned to
neutral before re-selecting drive. When using the forward/reverse switch, the forward or reverse lever must
be in neutral.
Forward/Reverse and Gear Change Lever

Figure 41.
F Forward drive R Reverse drive

N Neutral
Forward/Reverse Lever
The engine will only start when the forward/reverse lever is in the neutral position.
Stop the machine before you move the forward/reverse lever from forward to reverse drive or reverse to forward
drive.
Gear Change
The machine can be moved off in any gear, dependant on the ground conditions.
To select a gear, turn the barrel (+/-) on the lever so that the arrow marked on the barrel aligns with the required
gear.
The gear ratio given to each of the positions on the barrel switch is dependant on the transmission mode that
is selected.
Forward/Reverse Switch
The engine will only start when the forward/reverse switch is in the neutral position on both the steering column
and the loader control panel.
To select a drive direction, move the switch to the required position, forward or reverse.
66 9831/1850-4 66
Operation
Drive Controls
Figure 42.
A
R
A Forward/reverse switch F Forward drive
R Reverse drive N Neutral drive
Figure 43. Auxiliary control lever
N
R A
A Forward/reverse switch F Forward drive

R Reverse drive N Neutral drive
Service Brake Pedal

The service brake pedal is located on the floor of the cab. Refer to: Operator Station (Page 16).
Press the pedal to apply the brakes. Use the brakes to prevent the machine overspeeding down a slope. The
more the pedal is pressed, the sharper the braking action.
The brake lights should come on when the brakes are engaged. Do not drive the machine unless both brake
lights operate correctly.
Park Brake
WARNING The park brake must not be used to slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will be reduced. Whenever the park brake has been used
in an emergency the brake pack must be renewed.
67 9831/1850-4 67
Operation
Drive Controls
You must engage the park brake before you leave the cab. When the park brake is engaged, the transmission
drive is disconnected automatically.
To engage the park brake, push the button. Make sure that the indicator light on the instrument panel comes on.
1. Press the switch to engage the park brake.

1.1. Make sure that the indicator light on the instrument panel comes on.
2. Press the red safety catch and press the switch to release the park brake.
2.1. Make sure that the park brake warning light goes off.
When the park brake is engaged and the forward/reverse lever is moved away from neutral, an audible warning
will sound, the master warning light comes on and the 'park brake' message is shown. Refer to: Component
Locations (Page 16).
Figure 44.
A
MIRROR
L R
A Park brake switch
Manual Park Brake

Do not use its lever to adjust the park brake. The lever adjustment must remain permanently screwed all the
way in.
You must engage the park brake before you leave the cab. When the park brake is engaged, the transmission
drive is disconnected automatically.
1. To engage the park brake, pull the lever up as far as it will go (vertical).
1.1. Make sure that the park brake warning light on the front console comes on.
2. To release the park brake, squeeze the release lever and lower the lever fully. Make sure the indicator
light goes out
2.1. Make sure that the park brake warning light goes off.
When the park brake is engaged and the forward / reverse lever is moved away from Neutral (N), an audible
warning will sound, the master warning light comes on and the 'PARK BRAKE' message is shown.
Transmission Kickdown Switch
68 9831/1850-4 68
Operation
Drive Controls
Push the switch on the end of the forward/reverse control panel or on the control lever to operate the
transmission kickdown function.
Figure 45.
A Transmission kickdown switch
When the machine is in 2nd gear and the switch is pushed once, the transmission immediately shifts down to
1st gear. (speed dependant). Refer to: Transmission Mode (Page ).
If the switch is pushed again, the transmission will return to the original gear.
When the switch is pushed twice, (a double push) the transmission shifts to the next lowest gear (dependant
on speed and the A/M switch position). Refer to: Transmission Mode (Page ).
If the switch is pushed twice again, the transmission will then shift to the next lowest gear. The transmission
can shift through the gears in sequence to 1st gear if required.
If the switch is pushed once, the transmission will go back to autoshift.
69 9831/1850-4 69
Operation
Instruments
Instruments
Instrument Panel
Front Display
The gauges, warning and indicator lamps are grouped together on the instrument cluster. When a warning
lamp comes on, an alarm will sound.
Figure 46.
A
E
D C
A LCD (Liquid Crystal Display) screen B Warning and indicator lamps
C Fuel level gauge D Coolant temperature gauge
E Engine speed
The LCD shows the live machine information to the operator.
Fuel level gauge: The needle position shows the current level of fuel in the tank. Do not let the tank run dry,
or air can enter the fuel system.
Coolant temperature gauge: The needle position shows the current temperature of the engine coolant. Do not
let the needle rise into the red danger zone of the gauge.
Engine speed: The needle position shows the current speed of the engine.
Warning and Indicator Lamps

Figure 47.
A B C D E F G H
J K L M N P Q
Lamp test (daily): Turn the ignition key to the on position to do a start-up cycle. Only the lamps shown should
come on during the start-up cycle. Do not use the machine if any of the warning lamps do not come on, contact
your JCB dealer.
70 9831/1850-4 70
Operation
Instruments
Table 24.
A Direction indica- Audible/Visual. Illuminate with the direction indicators. Use the direction in-
tors dicators to signal before you turn the machine.
B Master warning Audible/Visual. If amber light illuminate then contact JCB dealer. If red light
illuminate then stop the machine immediately and contact your JCB dealer.
C Hazard warning Visual. Comes on with the hazard warning lights (even with the ignition key
in the off position). Switch on the hazard warning lights if your machine is a
possible hazard.
D Park brake Audible/Visual. The light will illuminate when the park brake is engaged.
E Sidelight Visual Only. Comes on when the roadlights are switched on.
F Main-beam lights Visual Only. Comes on when the main-beams are switched on.
G Rear fog lights Visual Only. Comes on when the rear fog lights are switched on.
H Engine pre-heat Visual. Illuminate if the engine pre-heater is active.
J Battery charging Audible/Visual. The lamp illuminates and buzzer will sound, if battery is not
condition charging while engine is running. If battery is charging, the lamp and buzzer
should go off a few seconds after the engine is started.
K High coolant tem- Audible/Visual. The light will illuminate when the engine coolant tempera-
perature ture is too high. Stop the machine immediately and remedy the fault.
L Low fuel level Visual. Illuminates when the fuel level is low.
M Engine oil pres- Audible/Visual. Illuminates if the engine oil pressure drops too far. Illumi-
sure nates when the ignition switch is set to position 1 before starting the engine
but should extinguish when the engine starts, if this light remains 'on' stop
the engine immediately.
N Brake system Audible/Visual. When the brake system charge pressure is low the lamp will
pressure come on. The buzzer will sound if the brake system charge pressure is low
when the engine is running.
P Differential lock Audible/Visual. Illuminates when the differential lock is switched on.
Q Low steering Audible/Visual. Illuminates when the pressure is low.
pressure
Normal Operation Screen

Figure 48.
A B C
H
D
G
F E
A Gear selection B Drivetrain icons
C Steer mode D Info area
E Clock F Chassis icons
G Engine speed H Ground speed
Gear Selection
The gear selection shows the current gear and direction.
71 9831/1850-4 71
Operation
Instruments
Drivetrain Icons
The drivetrain icons frame shows any currently enabled symbols from the current list.
Table 25.
Source Data Symbol Symbol on Condition Symbol off Condition
Secondary steering sys- Secondary steering pressure Secondary steering pressure
tem active (if fitted) equal or greater than 10 bar less than 10 bar ( 144.9 psi)
( 144.9 psi) or 0xFF 0xFF
Engine air filter blocked Input has been TRUE for 2 s NA

(remain on until key cycle)
DEF (Diesel Exhaust Refer to lamp status signal Refer to lamp status signal
Fluid)
Amber warning lamp Malfunction, rectify by next N/A

shift
Stop engine lamp Master warning, stop the ma- N/A

chine immediately
Service Service due < 20 h, Flashing > 20 h until next service

means service due < 0 h
High exhaust system High exhaust gas temperature N/A

temperature detected
SCR (Selective Catalytic Running refresh available N/A

Reduction) refresh
SCR refresh inhibit Running refresh inhibited N/A
72 9831/1850-4 72
Operation
Instruments
Info Area
The info area shows the live data using either a bar chart or numeric lists. Pressing the up/down buttons on
the display shall flip from one screen to the next.
Table 26.
Source Data Display Value at Bottom Value at top
Ad-Blu level 0% 100 %
Hydraulic oil temperature 10 °C ( 50.0 °F) 90 °C ( 193.9 °F)
Torque converter temper- 40 °C ( 103.9 °F) 120 °C ( 247.8 °F)

ature
Fuel use screen Volume of fuel remaining

Total fuel used (resettable)
Instantaneous fuel used
Average fuel used (resettable)
Information screen Current date

Machine hours
Distance
Hour to service
Setting screen Refer to Figure 47.
Clock
The clock frame shows the current time.
Chassis Icon
Table 27.
SRS (Smooth Ride Sys- SRS on SRS off
tem) State
Front work lamps Front work lamps or front aux- Front work lamp and front aux-
iliary work lamps on iliary work lamps off
73 9831/1850-4 73
Operation
Instruments

Rear work lamps Rear work lamps or rear auxil- Rear work lamp and rear auxil-
iary work lamps on iary work lamps off
Beacon Beacon on Beacon off
Heated rear screen Heated rear screen on Heated rear screen off
Hydraulics disabled Hydraulics disabled Hydraulics enabled
Ground Speed
The ground speed frame shows the current ground speed.
DEF Level
The LCD permanently displays the DEF level bar graph. Each bar represents approximately 10% of tank
volume.
Figure 49.
As the DEF level depletes to low, warning icons, notification symbols and warning icons are displayed. The
intensity of the warning symbols and indicator change as follows as the DEF level depletes further:
1. DEF gauge displayed to operator, 2 second audible warning present every 15 minutes. Navigation away
from the gauge is permitted.
2. Flashing amber notification symbol. Operator warning, fill up now.
Figure 50.
74 9831/1850-4 74
Operation
Instruments
3. DEF gauge displayed to operator, 2 second audible warning present every 5 minutes. Navigation away
from the gauge is not permitted.
4. Solid amber notification symbol. Derate condition initiated, fill up now.
Figure 51.
5. Flashing red notification symbol. Second stage derate condition, fill up now.
Figure 52.
6. Solid red notification symbol. Forced idle, machine unusable, fill up now.
Figure 53.
Secondary Display (Option)

The optional secondary display is installed beside the operator and provide a way for the operator to interact
with the machine.
Figure 54.
A Back button B Up button

C Home button D Down button
E Select button
The secondary display navigation can also be accessed by rotary switch panel as shown. Refer to Figure 55.
Help button and on- screen handbook button can only be accessed when park brake is applied.
75 9831/1850-4 75
Operation
Instruments
Figure 55.
G B
F C
E D
A Home button B Return button

C Rotary dial D On-screen handbook
E Function help button F Select button
G Blank
LCD Screen
The LCD screen has a home screen with a rear view camera on the left hand side. When the machine is in
reverse the rear view camera with fill the whole screen.
Figure 56.
B C D E
A F
A Rear view screen B Clock
C Climate control display D Machine hours
E Data area F Icon menu
On Screen Hand Book

The on screen handbook feature displays a view of the machine with area of interest highlighted with hotspots.
Refer to Figure 57.
The operator scrolls to the hotspot they want further information on using the rotary controller on onboard
buttons.
Select a button will display a page containing further information on that area of the machine.
76 9831/1850-4 76
Operation
Instruments
Figure 57.
The dial and select button on the dial allows the menu to be accessed and selected.
Figure 58.
77 9831/1850-4 77
Operation

General
WARNING Do not dismount a moving machine.
WARNING You or others can be killed or injured if you suddenly change from forward to reverse, or vice
versa, when travelling. The machine will immediately reverse direction without warning to others. Always
follow the recommended procedure for changing between forward and reverse drive.
When moving the machine, keep it under control at all times. Stay alert for obstructions and possible hazards.
Do not use the brake pedals as footrest.
Select the necessary gear before starting down a slope. Use the same gear you would use to go up the slope.
Do not change gear on the slope.
First gear gives the machine its maximum driving torque and engine braking effect. Use first gear when you:
• Drive through mud.

• Manoeuvre in tight spaces.
• Drive up or down steep slopes.
Approach deep mud with the front wheels straight.
Stop the machine and let the engine go to idle before you change gear from forward to reverse or from reverse
to forward.
Do not let the engine idle in reverse or forward gear for more than 5 min. The engine at idle in these positions
can cause overheating and damage to the transmission. Always select neutral when the time at idle will be
more than 5 min.
After you have warmed up the engine and tested the park brake, move off as described below.
1. Check your seat belt and seat.

1.1. Make sure that your seat belt is correctly fastened.
1.2. Make sure that the seat is correctly adjusted.
2. Check the lift arm is in the travel position.
3. Apply the brake pedal.
4. Release the park brake.
5. Select forward or reverse.
5.1. Make sure it is safe to move off, then release the brake pedal and push down on the accelerator pedal.
The machine will move smoothly away.
5.2. While the machine is travelling slowly, check the steering and brakes. Do not drive the machine unless
the steering and brakes are working correctly. If you are not sure, assume they are faulty.
78 9831/1850-4 78
Operation
Slopes
Slopes
General
WARNING Make sure that you have been trained and are familiar with the use of machines on slopes, and
understand the adverse affects that slopes and site conditions can have on stability. Never use the machine
on a slope if you do not understand the recommended practices for the use of machines in such applications.
There are a number of factors which can adversely affect the stability of the machine and the safety of the
machine and operator when used on a slope.
It is essential that a risk assessment of the work to be done is completed and that the operator complies with
any safety precautions that the assessment identifies.
Driving on Slopes
Driving Up and Down Slopes
WARNING Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground
conditions can be changed by rain, snow, ice etc. Check the site carefully. Going uphill, reverse when
unloaded or travel forwards when loaded. Going downhill, travel forwards when unloaded or reverse when
loaded. Take special care when moving across a slope. If the slope is too steep your machine could roll
over. If you must drive across a slope, keep the attachments close to the ground.
WARNING When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This
will increase stability.
To get the maximum traction when you drive on a slope:
• Drive an unladen machine forward down a slope and in reverse up a slope

• Drive a laden machine forward up a slope and in reverse down a slope.
Figure 59.
Driving Across Slopes

To get the maximum stability, operate the machine on solid, level ground. The stability of the machine is
decreased when it is driven across a slope.
When you drive across a slope, fully lower the lift arm and drive slowly at walking pace.
Lifting Operations on Slopes

WARNING Conducting lifting operations on slopes can be dangerous. The machine can become laterally
unstable and tip over. You and others can be seriously injured or killed.
Park the machine on solid, level ground and apply the park brake.
Lifting operations should not be undertaken on slopes unless the machine is level across its width (laterally
level).
It is recommended that the machine should be operated on firm, level ground wherever possible for maximum
machine stability. Where this is not possible, a risk assessment must be carried out by the operator before
attempting a lifting operation.
Make sure that you have taken in to account all factors that may affect machine stability before a lifting operation
is started when working on a slope.
79 9831/1850-4 79
Operation
Slopes
Working on Slopes
WARNING Conducting lifting operations on slopes can be dangerous. The machine can become laterally
unstable and tip over. You and others can be seriously injured or killed.
WARNING Stop the machine and apply the park brake before conducting any lifting operations.
The machine must be operated on solid, level ground wherever possible for maximum machine stability. Where
this is not possible a risk assessment must be carried out by the operator before attempting a lifting operation.
Make sure you have taken into account all factors that may affect machine stability before a lifting operation
is started when working on a slope.
Published values for rated capacities and tipping loads are specified for the machine on solid, level ground.
Actual values will be decreased based on actual operation conditions.
80 9831/1850-4 80
Operation
Driving the Machine
Driving the Machine

Towing Other Equipment
WARNING Examine the tow hitch and the trailer draw bar towing ring for signs of wear before each use.
A badly installed or worn hitch or towing ring could cause loss of the trailer and injury to yourself or other
people.
WARNING Do not exceed the permitted limits on trailer gross weight or hitch load. The machine may become
unstable.
WARNING Make sure the trailer hitch has correctly engaged and locked before driving off.
WARNING Make sure that all of the tow hitch daily checks are performed before using the tow hitch.
CAUTION Legal requirements for trailer brakes vary from country to country. Wherever you are working
you must obey all relevant laws.
Your machine can have an optional trailer pickup hydraulic tow hitch installed.
Before you use the tow hitch:
• Make sure all grease points on the tow hitch are topped up.
• Check the tow hitch for any oil leaks, if you find any oil leaks please contact your JCB dealer for service
support.
• Make sure the tow hitch operates correctly.
• Make sure you will be obeying all of the pertinent laws and regulations before you tow a trailer.
• Make sure that the trailer bar is suitable for your machine and has enough clearance to enable the machine
to turn without fouling.
• Make sure the tyre pressures are correct and that the loaded trailer does not exceed the maximum gross
trailer weight. Refer to: Towing Weights (Page 203).
The procedure to engage the trailer to the machine can vary dependant on the type of trailer. For more
information, refer to the trailer handbook.
If a person is available to help manoeuvre the trailer, they must stay away from the machine until the hydraulic
tow hitch is aligned correctly with the towing eye of the trailer.
The person must also stay away from the trailer or the machine until its park brake is engaged and the engine
has stopped.
81 9831/1850-4 81
Operation
General
WARNING Make sure it is clear overhead before raising the boom. Keep an adequate safe distance from
all electrical power lines. Contact your local power company for safety procedures.
CAUTION Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls.
If that happens you could lose control of the machine.
Control Layouts
WARNING Control lever/switch action may vary on machines, instructional labels near the levers/switches
show by symbols, which levers/switches cause what actions. Before operating control levers/switches check
the instructional label to make sure you select the desired action.
The levers are spring-loaded to their central hold positions. The speed of movement of the associated hydraulic
rams depends on how far you move a lever, the further you move the lever, the faster the ram action.
The rams will stay in any position until you move them with the levers or switches.
Lift Arm Controls
Multi Lever Controls

Figure 60.
1
5 3
5 4
2
8 4 1 7 3
1. Lift arms raise

2. Lift arms lower
3. Lift arms float
4. Shovel crowd
5. Shovel dump
6. Transmission disconnect
7. Horn
8. Transmission kickdown
82 9831/1850-4 82
Operation
Proportional Lever controls

Figure 61.
3 1
7
2
5 4
4 5
6
1
8 2
1. Lift arms raise

2. Lift arms lower
3. Lift arms float
4. Shovel crowd
5. Shovel dump
6. Transmission kickdown
7. Transmission disconnect
8. Forward/reverse switch
Auxiliary Circuit Controls

WARNING Before operating the auxiliary control system make sure that you are aware of all safety notices
that apply to the attachment you are using. Also make sure you have installed the attachment correctly and
have read its operator's manual.
A machine is supplied with one auxiliary service. A second auxiliary service can be installed as an option.
The auxiliary services are operated electrically by the auxiliary rollers/levers on the lift arm control lever or multi
lever. Refer to Figure 62. , Refer to Figure 63.
83 9831/1850-4 83
Operation
Figure 62. Proportional Lever Control

B C
A
E
A Auxiliary button (option) B Horn

C Transmission disconnect D Transmission kickdown switch
E Forward/reverse switch
Figure 63. Multi Lever Control

A B
C
D
F
G
A Shovel ram (crowd/dump) B Lift arm (lower/raise)
C Auxiliary 1 (option) D Auxiliary 2 (option)
E Transmission disconnect F Horn
G Transmission kickdown switch H Forward/reverse switch
The auxiliary services can operate the:
• Quickhitch locking-pins (first auxiliary service only).

• Attachments (both services).
• Auxiliary dump (if fitted): Auxiliary dump enables the operator to relieve pressure from the auxiliary
circuit(s) by diverting oil back to the hydraulic oil tank.
Auxiliary Dump Operation
1. To enable auxiliary dump press and hold the “hydraulic mode” button.
84 9831/1850-4 84
Operation

2. When this is pressed the second LED (Light Emitting Diode) function light is displayed to indicate that the
auxiliary dump function is active.
3. To dump the auxiliary circuits move the first auxiliary service actuator to full displacement, either forward
or backwards, whilst still pressing the “hydraulic mode” button.
4. The second LED function light will turn off during this process. This indicates that all conditions have been
met to open the auxiliary dump valve to return hydraulic oil to tank.
5. When the auxiliary service actuator is released and the “hydraulic mode” button is still pressed the second
LED function light is displayed to indicate that the auxiliary dump function is still active.
6. When the “hydraulic mode” button is released the second LED function light will turn off. The hydraulic
mode button will return to its previous state.
6.1. The “hydraulic mode” button is also used for precision hydraulics. When auxiliary dump is activated
and de-activated the precision hydraulics will remain in its previous state as indicated by the first LED
function light.
7. If any of the following events happen during the use of auxiliary dump, the function will be disabled
7.1. Hydraulic isolation switch is active.
7.2. Hydraulic mode switch is released
7.3. The Auxiliary service actuator is not at full displacement
8. Refer to: Connecting/Disconnecting Hydraulic Hoses (Page 110).
Lower the Lift Arms in an Emergency

The product has an accumulator which stores a small quantity of hydraulic pressure to be used in an emergency
(for example engine failure). This hydraulic pressure must be used to lower the lift arms to a safe position.
Do not try to operate the other machine functions as this will decrease the hydraulic pressure in the accumulator
and it may then not be possible to lower the lift arms.
Operate all the functions on the loader controls lever to release the remaining pressure.
85 9831/1850-4 85
Operation
Lifting and Loading
Lifting and Loading

General
WARNING A high load can block your view and reduce the machine's stability. Travel with the load low to
the ground. Travel slowly and with caution over rough, muddy or loose surfaces.
WARNING Do not use the machine for object handling unless it is equipped for this purpose. Without the
relevant devices the machine can become unstable and tip over. You and others could be seriously injured
or killed.
WARNING Before you lift a load with the machine, you must read and understand this section. Failure to
take the precautions shown can result in death or injury.
If your machine is not installed with a lifting point (for example a hook or shackle), hose burst check valves,
load charts and an overload warning system then it must not be used for object handling.
If your machine is not installed with this equipment you must only use the machine for earthmoving purposes.
Lifting (Object Handling) Regulations

The owner and/or operator must make sure that they fully understand the laws and regulations concerning the
use of the JCB machine as an earthmover and for lifting. Consult your JCB dealer for more information.
In certain countries safety regulations in force call for the application of specific safety factors. Consult your
JCB dealer for more information.
All figures and lift capacities (if applicable) in this publication are based on the machine being on level, solid
ground.
Safe Working Loads

The maximum load which may be lifted depends on the equipment attached to the machine and the laws and
regulations in force at the time and in the country in which the machine is being used.
If your machine is equipped to be operated under 'Exemption Certificate' rules, your Exemption Certificate will
specify the safe working loads.
Fit for Purpose Tests for Lifting Equipment

All lifting equipment (for example forks, lifting hooks and shackles) needs regular inspections and testing by a
competent person to make sure they are fit for purpose. These may be needed every six months or at least
annually in some countries to meet and comply with legislation and for insurance purposes. Check with your
local JCB dealer for further advice.
86 9831/1850-4 86
Operation

General
WARNING Stop the machine and apply the park brake before conducting any lifting operations.
WARNING Under no circumstances should personnel be lifted into the air without using an approved and
properly secured platform. Failure to follow this warning could result in death or serious injury.
WARNING Maintain correct tyre pressures to avoid upsetting the lateral stability of the machine. Inspect
tyres daily for signs of damage, cuts or embedded objects which could cause loss of pressure.
WARNING Loading and unloading on soft or uneven ground can be hazardous. The machine could tip over
and you could be killed or injured. Make sure that the ground is level and firm before loading and unloading.
Whenever possible, avoid soft or uneven ground when carrying a load.
WARNING Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity.
WARNING Operating the boom while you travel can cause accidents. You will not have total control of the
machine. Never operate the boom when you travel.
WARNING A high load can block your view and reduce the machine's stability. Travel with the load low to
the ground. Travel slowly and with caution over rough, muddy or loose surfaces.
WARNING Keep yourself and all others away from the lifting mechanism. Never allow persons to walk below
a raised cab at any time. Do not carry passengers.
WARNING In the event of a breakdown with the boom not in the normal travel position, contact your local
JCB dealer for assistance with getting the boom and load back to a safe position.
CAUTION Make sure you know the weight of the load before trying to lift it. Raise the load only a few
centimetres at first, to check that the machine is stable. Lower the load straight away if the machine begins
to feel unstable. Do not exceed the loading limits shown on the Load Charts.
CAUTION Travelling too fast or with the load too high can make the machine tip over. Keep the load close to
the ground when travelling. Do not go faster than walking pace when the machine is carrying a load. Drive
carefully over bumps and curbs. Do not operate the boom/carriage controls while the machine is moving.
CAUTION Loads stacked on uneven ground can topple. Never stack loads on uneven ground.
CAUTION A raised boom can strike overhead objects. Always check for overhead clearance before raising
the boom.
Practice with palleted loads first. Do not handle awkward loads until you can handle palleted loads safely and
confidently.
Make sure that any location where a load is to be placed is strong enough to hold the weight of the load.
Look in the direction of travel and keep a clear view of the way ahead. Seek assistance if forward vision is
obscured by a bulky load. Particular care is required when driving off level ground.Refer to: Slopes (Page 79).
Do not carry stacked loads that are higher than the fork carriage.
Drive at a speed consistent with conditions. Slow down when travelling on wet, slippery or loose surfaces.
Drive with care to minimise bouncing over rough surfaces. This can result in loss of load.
Lifting and Loading Operations

Ensure that all local and national legislation governing operations such as lifting and loading are fully satisfied
before operating the machine. This should include the selection of the correct model of machine for the
operation, and the planning of the lifting operation itself.
Further information concerning the safe use of lifting and other equipment in the UK is available from the HSE
information line on 0541 545500 or on the world wide web at: http://www.hse.gov.uk
87 9831/1850-4 87
Operation
Other countries and territories have their own legislation similar to the above. Be sure that you are aware of all
local and national legislation governing lifting and loading operations where you are operating.
Filling the Shovel

WARNING When loading with material from a high bank or pile, remove any overhang first. Watch out for
sliding material. If overhanging material falls, you and your machine could be buried.
This information is not intended to be comprehensive, nor to be a substitute for adequate training. Make sure
you are trained before you use an attachment.
1. Approach the pile with the shovel level and skimming the ground.
2. Do not load the shovel with the lift arm extended. This can cause serious damage to the lift arm.
3. When you are loading from a pile of loose material, start at the bottom and follow up its face.
4. When you are loading from a pile of tightly packed material, start at the top and work down.
5. When you are removing material from a high pile, start at a shovel's height from the base. When the height
of the pile has been reduced, begin loading from the base.
6. As the shovel enters the pile, start rolling the shovel back while raising it at the same time. This will sweep
the shovel up the pile, gathering material as it goes.
Figure 64.
7. Try to fill the shovel in one pass. Half full shovels are less productive.
8. When moving the load, roll the shovel fully back to prevent spillage.
Loading a Truck
Put the truck(s) at an angle of about 45 ° to the pile. This cuts out unnecessary manoeuvring. Allow enough
distance for the shovel to reach its unloading height while you are travelling, without slowing down.
Keep the wind on your back. This keeps dust away from you and your machine.
Move your machine as close as possible to the truck before unloading.
If the truck body is about as long as a shovel's width, tip the load into the centre of the truck. If the truck is two
shovel width's long or more, load the front of the truck first.
Do not dump the material in one sudden movement. Roll the shovel forward in stages until it is empty. Use the
control lever to rock the shovel back and forth to loosen any sticky material.
88 9831/1850-4 88
Operation
Figure 65.
Adjusting the Lift Arm
Machine Adjustments
The machines have a lift arms lift reset proximity switch and a shovel reset proximity switch.
The lift arms re-set proximity switch releases the control lever detent at a pre-determined angle when the lift
arms are being lifted.
The shovel reset proximity switch releases the control lever detent when the shovel is at a pre-determined
angle when it is being crowded.
The machine has the option of forks (attached on-site) to replace the shovel. With this option, two 'shovel re-
set' proximity-switches are installed and an additional rocker switch is installed in the cab.
Set the Lift Arms Proximity Switch

1. Park the machine on hard, level ground.
Refer to: Stopping and Parking (Page 52).
2. Operate the control lever to lift the lift arms to the required height.
3. Loosen the nuts.
4. Move the proximity switch to the required position in-line with the lift boss arm.
5. Tighten the adjusting slot nut first (tighten the pivot nut last to prevent the bracket moving).
6. Make sure that the proximity switch operates automatically at the correct hieght.
6.1. Operate the control lever to raise the lift arms.
6.2. Release the control lever when the lift arms start to rise. The lift arms should stop at the preset height.
7. If necessary, adjust the position of the proximity switch again.
The detent position is only selectable when the proximity switch is out of range of the sensor bar.
89 9831/1850-4 89
Operation
Figure 66.
A Proximity switch B Lift arm

C Nut - pivot D Nut - adjusting slot
Set the Attachment Angle Proximity Switch (HT Machines)

1. Park the machine on hard level ground.
2. Set the shovel flat on the ground.
3. Loosen the locknuts, then adjust the bar so that its end is aligned with the proximity switch.
4. Tighten the locknuts.
5. Make sure the proximity switch operates automatically at the correct position:
5.1. Operate the control lever to raise the lift arms sufficiently for the attachment to clear the ground when
its dumped.
5.2. Fully dump the attachment.
5.3. Crowd the attachment, release the control lever when the attachment starts to move. The attachment
should stop at the preset angle.
6. If necessary, adjust the position of the proximity switch again.
The detent position is only selectable when the proximity switch is out of range of the sensor bar.
90 9831/1850-4 90
Operation
Figure 67.
A Locknut B Proximity switch
91 9831/1850-4 91
Operation

General
The operator must set the controls to obtain the best working environment in the operator station.
Close doors and windows for best HVAC (Heating Ventilation Air Conditioning) performance and in dusty
conditions.
Poor ventilated air can cause tiredness. Do not operate the machine for long periods without ventilation or with
the operator station fully closed and the fan turned off.
Air-Conditioning Controls
Manual Air-Conditioning Controls With Mode

In order to pressurise the cab environment all doors and windows must be fully closed, all vents open, the
ATC / HVAC system switched into 100% fresh air mode and the fan on speed maximum, please note as filter
life deteriorates the air flow will reduce reducing cabin pressure.
Figure 68.
A B C D E
A Fan control switch B Air-conditioning switch

C Windscreen and operator mode switch (option) D Re-circulation switch
E Temperature control switch
The HVAC (Heating Ventilation Air Conditioning)manual control switch has the following controls:
1. Fan speed regulator: The fan speed regulator is attached to a four position switch. This switch controls the
air velocity through the duct system and the heater core.
2. Air-conditioning switch: When switched off, the air flow through the HVAC system is stopped.
3. Windscreen and operator mode switch: Use this switch to operate the forward mode, windscreen and
operator mode.
4. Re-circulation switch: When flow control is selected to fresh air position, fresh air is brought in from outside
the cab. Fresh air increases air pressure in the cab, thus any openings leak outward. This eliminates cold
spots and provides a more uniform cab temperature.
5. Temperature regulator: This controls the water valve. A water valve is the primary control for a basic heater
system. When the valve is open, hot engine coolant flows through the heater core and back to the engine.
The operator can adjust the control to modulate coolant flow through the heater core.
92 9831/1850-4 92
Operation
ATC (Automatic Temperature Control) Panel

Figure 69.
B AC D E F G
A AK J H
A Fan speed - Down B Fan speed - Up
C Demist/defrost D Air recirculation
E Full fresh air F Automatic mode
G Temperature - Up H Temperature - Down
J Air-conditioning on/off K Max cold
The ATC (Automatic Temperature Control) panel has the following controls:
1. Fan speed up and down: The fan speed allows you to manually control the air velocity through the duct
system and the heater/air-conditioning unit. When you operate these buttons the ATC system will not
operate in auto mode until the auto button is activated again. The ATC system can be turned off by pressing
the fan button.
2. Demist/defrost: The demist/defrost should be activated when defrosting/demisting of the front screen
is required, the system will automatically adjust it’s setting to maximize defrost/demist performance. To
deactivate this feature press this button again.
3. Air recirculation: Adjust the air intake flap and shuts off fresh air and go to recirculating air mode.
4. Full fresh air: Adjusts the air intake flap and shuts off recirculating air and go to full fresh air mode.
5. Automatic mode: The automatic mode is controls the fan speed, air-conditioning and heating performance
of the unit automatically to meet the required set temperature.
5.1. When the in cab ambient air temperature is vastly different to the operator set temperature the fan
speed will increase rapidly to cool or heat the cab for a short period of time and then slow back down
as the temperatures become aligned.
6. Temperature up and down: Allow the operator to control the in cab temperature to their required setting.
7. Air-conditioning: Allows you to switch the air-conditioning function on and off. To maximise the air-
conditioning performance it’s advised all windows are to be kept shut.
8. Max cold: Automatically ramps up the fan speed and air-conditioning performance to achieve maximum
cooling in the cab. To deactivate this feature press this button again.
93 9831/1850-4 93
Operation
Power Sockets
Power Sockets
Auxiliary Power Socket
Your machine may be fitted with one or more 12 V or 24 V auxiliary power sockets, which can be used for
mobile phone chargers or other 12 V or 24 V powered devices. Refer to: Component Locations (Page 16).
Only connect items which are compatible with the power rating of the socket and have the correct plug.
Always operate the engine during the prolonged use of the electrical accessories, or the battery can discharge.
Make sure that the socket cap is closed when the socket is not in use.
The socket cap states if the socket is 12 V or 24 V .
94 9831/1850-4 94
Operation
Fire Extinguisher
Fire Extinguisher
General
Location
A fire extinguisher is located in the cab, held in position by a stowage bracket. Make sure you know where the
extinguisher is located on your machine.
Keep the fire extinguisher in the bracket until you need to use it.
Operation
WARNING Do not use the fire extinguisher in a confined space. Make sure that the area is well ventilated
during and after using the fire extinguisher.
WARNING After any use, the extinguisher must be replaced or serviced.
Make sure that you understand how to use the fire extinguisher. If necessary, refer to the instructions found
on the fire extinguisher.
Only try to extinguish a fire if the circumstances permit and your safety is not endangered. If necessary, contact
your nearest fire department.
Using the fire extinguisher:
1. If circumstances permit and your safety is not endangered, move the machine to a safe place to prevent
the fire from spreading.
2. Remove the fire extinguisher from its stowage bracket.
3. Remove the safety pin.
4. Aim directly at the fire from an upwind position, if possible.
5. Squeeze the trigger to operate the fire extinguisher, release the trigger to stop the flow.
Figure 70.
A B
A Safety pin B Trigger
The fire extinguisher should be inspected daily. See Routine Maintenance, Fire Extinguisher (If fitted).
95 9831/1850-4 95
Operation

General
If the machine becomes disabled, the machine must be made safe, lifted onto a transporter and moved to a
location where it can be repaired.
You must contact your nearest JCB dealer before you try to tow, winch or push the machine.
Towing, winching or pushing the machine without following the correct procedure will damage parts of the
hydraulic system. If possible, repair the disabled machine where it stands.
Getting the Machine Unstuck
If the wheels are stuck and are not turning, do not apply full power for more than 10 s in forward or reverse
drive. Full power for more than 10 s will cause the transmission to overheat.
If the transmission overheats during this procedure:
1. Put the transmission in neutral. Do not move the transmission from the neutral to the forward drive or
reverse drive positions when the engine is above idle.
2. Run the engine at 1200-1500 rpm until it is cool.
If the machine is stuck in sand, snow, or mud, it may be possible to 'rock' the machine out:
1. Put the transmission in forward drive.

2. Apply a steady light pressure to the accelerator pedal (never apply full pressure). When the machine has
moved forward as far as possible, engage and hold the foot brake.
3. When the engine has returned to idle, put the transmission in reverse drive.
4. Release the foot brake and apply a steady light pressure to the accelerator pedal. When the machine has
moved backwards as far as possible, engage and hold the foot brake.
5. Let the engine return to idle.
Do the procedure again until the machine is free or can not move any further backwards or forwards.
Jump-Starting the Engine

WARNING In temperatures below freezing, the battery electrolyte may freeze if the battery is discharged
or poorly charged. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
If you try to charge a frozen battery or jump-start and run the engine, the battery could explode.
Batteries produce a flammable gas, which is explosive. Do not smoke when checking the electrolyte levels.
When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This
prevents any chance of sparks near the battery.
Switch off all circuits which are not controlled by the ignition key.
Do not connect the booster (slave) supply directly across the starter motor.
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 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
96 9831/1850-4 96
Operation
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. The negative (-) terminal on the battery
is connected to frame earth.
1. The park brake should have been engaged when the machine was last parked. If it is not engaged, engage
it now. Make sure machine is in neutral. If necessary block the machine to prevent it moving.
2. Depending on your type of machine, lower the lift arms / forks or attachments (if fitted) to the ground, if they
are not already there. They may lower under their own weight when you operate the controls. Operate the
controls carefully to control the rate of descent. If your machine is fitted with hose burst protection valves,
you may not be able to lower lift arms. In this case make sure you install the safety strut(s).
3. Set all switches in the cab to their off positions.
4. Get access to the battery.
5. Connect the booster cables:
5.1. Connect the positive booster cable to the positive (+) terminal on the machine battery. Connect the
other end of this cable to the positive (+) terminal of the booster supply.
5.2. Connect the negative (-) booster cable to a good frame earth on the machine, away from and below
the battery. A good frame earth is a part of the machine frame, free from paint and dirt. Do not use
a pivot pin for an earth.
5.3. Connect the other end of this cable to the negative (-) terminal on the booster supply.
6. Do the pre-start checks.
7. Start the engine.
8. Disconnect the booster cables:
8.1. Disconnect the negative booster cable from the machine frame earth. Then disconnect if from the
booster supply.
8.2. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect
it from the booster supply.
Retrieval
Towing a machine too far or too fast can damage the transmission. The towing vehicle(s) must have enough
pulling and braking power to move and stop the machine.
Operator recovery of a disabled machine is only possible over a short distance, if there is sufficient residual
pressure in the braking system
1. Make sure the park brake is engaged, the transmission is in neutral and the engine is off. If necessary,
block the wheels of the machine.
2. Prepare the lift arms (if engine and hydraulics are working):
2.1. If the engine and hydraulic systems are not damaged, lift the shovel above the ground by
Distance: 900 mm
2.2. Fully crowd the shovel. The machine in this position can have a straight pull from the recovery point.
3. Prepare the lift arms (if the engine and hydraulics are not working):
3.1. Use the applicable equipment to lift the shovel and secure it above the ground by
Distance: 900 mm
97 9831/1850-4 97
Operation
3.2. Crowd the shovel. Secure the shovel in position.

4. Make sure that both the retrieval chains are suitable and that you use both the retrieval points when
retrieving the machine. Attach the retrieval chains to the retrieval points located on both sides of the machine
on the chassis in the rear wheel arches and attach to the correct point on the towing vehicle. If you are
in any doubt about the suitability of the retrieval chains, do not use them. The retrieval chains should be
rated to at least
Weight/Force: 190,000 N
5. Make sure that the retrieval chains are arranged to work within the angular range shown
98 9831/1850-4 98
Operation
Figure 71.
B A
B
C
D B
D
A Retrieval points B Retrieval chains
C Maximum deflection from the horizontal axis as D Maximum deflection from the vertical axis as
shown = 10 ° shown = 10 °
6. Disengage the park brake and make sure the transmission is in neutral. Remove any blocks from the
wheels. If this is not possible to release the park brake you will need to contact your JCB dealer.
7. Make sure you only pull the machine in the direction of rotation of the wheels.
99 9831/1850-4 99
Operation
Figure 72.
When retrieving the machine, make sure you understand what the towing driver will be doing. Obey their
instructions and all relevant regulations.
The machines retrieval points conform to ISO (International Organization for Standardization):10532. The
maximum permissible retrieval force is 190,000 N
Secondary Steer System (if installed)

On some machines, if the steering wheel has to be turned when the machine is disabled and the engine is
stopped, push and hold the secondary steer system switch. When the steering wheel is turned, the pump is
heard running and the articulation of the chassis is felt. Test the switch once a month.
The full operation of the steering system is only achieved when the machine is moving.
Loader Arm (Emergency Operation)

DANGER Before lowering the attachments to the ground, make sure that the machine and the area around
it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments,
or get caught in the linkages.
The machine has an accumulator which stores a small quantity of hydraulic pressure to be used in an
emergency (for example engine failure). This hydraulic pressure must be used to lower the loader arms to a
safe position.
Do not try to operate the other machine functions as this will decrease the hydraulic pressure in the accumulator
and it may then not be possible to lower the loader arms.
Operate all the functions on the loader controls lever to release the remaining pressure.
100 9831/1850-4 100

Operation
Lifting the Machine
Lifting the Machine

General
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you
will be working with other people, make sure any hand signals that may be used are understood by everybody.
Worksites can be noisy, do not rely on spoken commands.
DANGER! Do not stand underneath the raised load during the lifting/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.
CAUTION! You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of
the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that
lifting equipment is in good condition and complies with all local regulations.
Contact your JCB dealer for help and advice before you do this procedure.
1. Remove all the attachments.

Refer to: Attachments (Page 109).
2. Make the machine safe with the lift arm lowered.
Refer to: Maintenance Positions (Page 145).
3. Install the articulation lock in the transport position.
Refer to: Articulation Lock (Page 58).
4. Remove all loose equipment from machine exterior.
5. Remove the starter key and leave the machine.
6. Confirm the unladen weight of the machine.
Refer to: Static Dimensions (Page 197).
7. Look for the labels to identify the correct sling points.
8. Attach the lifting equipment to the sling points.
9. Take the weight of the machine. When lifting the machine, a suitable spreader frame must be used to make
sure the pull on each sling point is vertical and the machine is level.
10. Check that the lifting eye is positioned directly above the machine centre of gravity.
11. Lift the machine, make sure the lifting equipment does not catch the machine.
Figure 73.
A Sling points
101 9831/1850-4 101

Operation
Lifting the Machine
Figure 74.
B Sling point label
102 9831/1850-4 102

Operation

General
WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any
machine, attachments or parts that may move during transit must be adequately secured.
WARNING Make sure that the ramp incline does not exceed the machine's operational limits.
CAUTION 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 tracks. Make sure the machine will not
foul on the ramp angle.
Make sure that the transporting machine is suitable for the dimensions of your machine. Refer to: Static
Dimensions (Page 197).
1. Put the trailer in position:

1.1. If the machine is serviceable, use any available position.
1.2. If the machine is unserviceable, you must align the trailer with the rear of the machine.
2. Put blocks at the front and rear of the trailer wheels.
3. Make sure the ramps onto the trailer are in the correct position and are attached securely.
4. Set the lift arms to the road travel position
5. Move the machine onto the trailer:
5.1. Carefully reverse a serviceable machine onto the trailer.
5.2. Lift an unserviceable machine into position on the trailer.
6. Engage the park brake and set the transmission to the neutral position. Put blocks at the front and rear
of all four tyres.
7. Put blocks at the front and rear of all four tyres of the machine.
8. When the machine is safely in position, lower the attachment onto the trailer, then stop the engine.
9. Install the articulation lock
10. Make sure the total height of the load is within regulations, adjust the height if necessary.
11. Put a cover on the exhaust stack
12. Use the tie-down points to secure the machine to the trailer with suitable chains or restraints. The chains
or restraints used must have a work load limit equal to or higher than the requirement and a factor of safety
equal to or greater than 2. The requirement is
Weight/Force: 100,000 N
103 9831/1850-4 103

Operation
Figure 75.
A
B
F C
F
C
E A B E
A Front axle tie-down points (both sides) B Rear tie down points (both sides)
C Angle = 30° to 45° D Angle = 5° to 15° (D is the angle between the
trailer / lorry loading plane and the chain (rear).
E Restraints F Front top angle projection. Angle = 30° to 55°
G Front chain angle. Angle = 0° to 20° (G is the
angle between the trailer / lorry loading plane
and the chain (front).
Figure 76.
12.1. Make sure the chains or restraints are arranged at the correct angles as shown
12.2. Measure the maximum height of the machine from the ground. Make sure the driver knows the
clearance height before driving away.
104 9831/1850-4 104

Operation
General
Operating in Dusty or Sandy Areas
1. Air Cleaner. Frequently check, clean or replace the elements regardless of the inspection interval. (Not
the safety element).
2. Securely tighten the hydraulic oil tank filler cap to prevent sand and dust from entering the hydraulic system.
3. Check for debris accumulation below the engine.
Operating in Coastal Regions

1. Check that all the plugs, bolts and fasteners are all tightened properly.
2. After daily operations, wash the machine thoroughly and take special care when cleaning the electrical
devices and hydraulic cylinders to prevent salt entry and eventual corrosion.
Operating on Wet or Soft Ground

1. Clean the Machine. Moisture or mud will cause the paint, wiring and metallic parts to deteriorate. When
operating the machine keep it as dry as possible and regularly grease the machine.
2. Check for debris accumulation below the engine.
Operating in Low Temperatures

1. Use the correct viscosity engine lubricating oil.
Refer to: Fluids, Lubricants and Capacities (Page 207).
2. Use the correct viscosity hydraulic oil.
3. If available, use a low temperature diesel fuel.
4. Use the correct coolant mixture.
5. Keep the battery at full charge.
6. Fill the fuel tank at the end of each work period, this will help to prevent condensation forming on the tank
walls.
7. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin.
8. Install a cold weather starting aid. In very low temperatures (less than the value shown) additional starting
aids may be needed. For example are fuel, oil and coolant heaters. Ask your JCB dealer for advice.
Temperature: -18 °C ( -0.4 °F)
9. Before the engine is started, remove any snow from the engine compartment or snow could get into the
air filter.
Operating in Extremely Low Temperatures

In extremely low temperatures (below 0 °C ( 32.0 °F)) special care must be taken. Extend the warm up time
and if applicable cover the front faces of the radiator and oil cooler. After warm up, remove the covers.
1. Until the machine is thoroughly warmed up never try to operate the travel system, or damage can occur.
2. Before the machine is operated after a warm up, make sure that the services all operate correctly. A time
lag may occur when selecting these services if the hydraulic oil is not sufficiently warm.
3. If the machine will be left outside for more than one day without being used, remove the battery and take
it indoors.
105 9831/1850-4 105

Operation
4. Drain the water collected in the fuel system to prevent it freezing.

5. Clean the machine after use and put it on wooden blocks. Keep the rams as fully retracted as possible.
Remove any water from the exposed portion of the piston rods.
6. Additional low temperature fuel and lubricants and batteries may be required. Contact your local JCB dealer
for advice.
Operating in High Temperatures

1. Use the correct viscosity engine lubricating oil.
2. Use the correct coolant mixture.
3. Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks.
4. Keep the cooling pack and engine clean, regularly remove dirt and debris from the cooling pack and the
engine.
5. Check the fan belt regularly.
6. Check the air vents. Make sure that the air vents to and from the engine compartment are not blocked.
7. Check the engine pre-cleaner regularly (if installed).
8. Check the battery electrolyte level.
Cab Filters
Cab Filters
There are two different filters available for the cab heater unit/air-conditioning unit.
The cab is not air tight or pressurised. The cab filter is provided for comfort only, it does not provide complete
protection against the environment in which the machine is used. The appropriate PPE (Personal Protective
Equipment) must be worn if the machine is used in hazardous environments.
Standard Filter
A solid particle filter used for general applications which do not require special filtration.
Carbon Filter
A solid particle, odour filter used for general applications which do not require special filtration.
106 9831/1850-4 106

Operation
Refuelling
Refuelling
General
CAUTION Spilt fuel may cause skidding and therefore accidents. Clean any spilt fuel immediately.
Do not use fuel to clean the machine.
When filling with fuel, choose a well aired and ventilated area.
Notice: Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of.
Low Fuel Levels
If you operate the machine on very low fuel levels, then air can enter the fuel system. To prevent the entry of
air, always add more fuel when the fuel gauge shows a low level of fuel.
If air enters the fuel system, the engine speed will vary dramatically and low power will be experienced. The
symptoms may be made worse when the machine operates on steep slopes.
If you increase the engine speed or load when there is air in the fuel system, then damage to the engine can
occur.
Filling the Tank

WARNING Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the
petrol will form flammable vapours.
Notice: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the
failure is attributed to the quality and grade of the fuel used.
Notice: No warranty liability whatsoever will be accepted for failure of the emissions control system where
the failure is attributed to contamination of the diesel exhaust fluid (DEF).
the failure is attributed to contamination of the diesel fuel.
the failure is attributed to the quality and grade of the diesel exhaust fluid (DEF) used.
Refer to: Fluids, Lubricants and Capacities (Page 207). If you use the incorrect type of fuel or fuel which is
contaminated, then damage to the fuel injection system can occur.
Fill the fuel tank and DEF (Diesel Exhaust Fluid) tank (if applicable) at the end of each work period, this will
help to prevent condensation forming on the tank walls.
Always replenish the DEF tank at the same as you refill the diesel tank. It is recommended that the DEF tank
is not continually run down to the minimum, as this may drag contamination into the system.
DEF has a totally separate tank of its own. You can recognise your DEF tank by its blue cap or an AdBlue
® label.
Filling the Diesel Tank

Notice: Make sure that you use the fuel filler and not the DEF filler. Even small amounts of fuel in the DEF
tank may damage the system. If there is any possibility that the DEF system has been contaminated with
fuel, the engine must not be started before cleaning the system. Contact your JCB dealer.

2. If the machine has a protective flap, you must move the flap to get access to the filler cap. Lift the corner
of the protective flap then attach to the hook.
3. Remove all unwanted material around the diesel fuel cap.
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Operation
Refuelling
4. Remove the diesel fuel tank cap. Refer to Figure 77.

5. Add the fuel through the filler neck as necessary.
6. Install the diesel fuel tank cap.
7. Lock the diesel fuel tank cap to prevent theft and tampering.
8. Lower the protective flap.
Filling the Diesel Exhaust Fluid Tank

Notice: Make sure that you use the DEF filler and not the fuel filler. Even small amounts of DEF in the fuel
tank may damage the system. If there is any possibility that the fuel system has been contaminated with
DEF, the engine must not be started before cleaning the system. Contact your JCB dealer.

2. Remove all unwanted material around the DEF cap.
3. Remove the DEF cap. Refer to Figure 77.
4. Add the DEF through the filler neck as necessary.
5. Install the DEF cap.
6. Lock the DEF cap to prevent theft and tampering.
Figure 77.
A DEF tank cap (blue) B DEF tank
108 9831/1850-4 108

Attachments
Attachments
Introduction
Attachments
Use only the JCB approved attachments that are specified for your machine. Operating with non-specified
attachments can overload the machine, causing possible damage and machine instability which could result
in injury to yourself or others.
The use of non-approved attachments could invalidate your warranty.
Metal Splinters
You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or
copper drift to remove and install metal pins. Always wear personal protective equipment.
Attachments
If you have an attachment which is not covered in the Operator's Manual do not install it, use it or remove it until
you have obtained, read and understood the pertinent information. Install attachments only on the machines
for which they were designed.
Some attachments are supplied with the instructions on the safety, installation, removal, operation and
maintenance procedures. Read and fully understand these procedures before the attachment is installed, used
and serviced. If there is anything you do not understand, ask your JCB dealer.
Before you use an attachment, make sure you understand how the attachment will affect the operational safety.
When an attachment is installed, there may be changes in the machines centre of gravity or overall dimensions.
These change can effect for example, the machine stability, the gradients on which it is safe to operate or the
safe distance from power lines.
Practice with an attachment off the job before you work with it for the first time.
A JCB attachment is designed and manufactured specifically to suit the machines hydraulic system, mounting
components and safe load requirements.
An attachment which is not designed for use with the machine can cause damage and create a safety hazard
for which JCB cannot be held responsible. Also the machines warranty and any other legislative compliance
can be affected by the use of non JCB approved attachments.
If your machine needs the hydraulic system adapting to use an auxiliary attachment, you must consult your
JCB dealer. Only suitably qualified personnel must re-route the hydraulic hoses.
All optional attachments must be used within the limits for the machine and will have limits on their operation,
for example, the lifting capacity, speeds, hydraulic flow rates. Always check the instruction supplied with the
attachment, or if in doubt check with a JCB Dealer for advice. Some specification limits may also be shown
on the data/rating plate on the attachment.
This section of the Operator's Manual includes general information on the operation of the attachment and the
procedures for the installation and removal of the attachment.
Attachments for your Machine

Attachments will help increase the productivity of your machine, for more information contact your JCB dealer.
Remember, do not operate an attachment until you have read and fully understand the attachment operating
instructions.
Do not operate or work with attachments until the machine hydraulic oil has reached its normal working
temperature.
Notice: Some attachments may contact parts of the machine when in the fully folded position. Take extra care
to avoid damage to the machine.
109 9831/1850-4 109

Attachments
Connecting/Disconnecting Hydraulic Hoses

WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid
under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks
and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
WARNING Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic
hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose
service line has been vented before connecting or removing hoses. Do not start the engine with loose or
open hose connections.
Some attachments are hydraulically powered. The following procedures show how to connect and disconnect
the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Vent the hydraulic system.
Refer to: Discharge (Page 186).
3. Check the hoses and adaptors for damage.
4. Connect the hoses:
4.1. Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail
or the connections to loosen.
Figure 78.
4.2. Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose
to fail.
4.3. Make sure that the hose does not touch parts which can rub or cause abrasion.
4.4. Use the hose clamps (where possible) to support long hose runs and keep the hoses away from
moving parts, etc.
Figure 79.
4.5. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs
the change.
110 9831/1850-4 110

Attachments
Figure 80.
5. Check for leaks:

5.1. Start the engine.
5.2. Operate the related controls to increase the pressure in the hydraulic system.
5.3. Stop the engine then remove the ignition key.
5.4. Check for indications of leakage at the hose connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

3. Disconnect the hoses.
4. Check the hoses and adaptors for damage.
Refer to: Checking For Damage (Page 129).
5. If necessary, install the blanking caps.
6. Check for leaks:
6.1. Start the engine.
6.2. Operate the related controls to increase the pressure in the hydraulic system.
6.3. Stop the engine then remove the ignition key.
6.4. Check for indications of leakage at the hose connections. Correct, as necessary.
Quick Release Couplings

WARNING The external surfaces of the couplings must be clean before connecting or disconnecting.
Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or
seriously injured by faulty quick release couplings.
The flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently.
Generally, your machine pipework will be installed with a female coupling and a male coupling. The optional
attachment hoses will also be installed with a female coupling and a male coupling.
111 9831/1850-4 111

Attachments
Figure 81.
A B
A Female coupling B Male coupling
The quick release couplings will be trouble free and relatively easy to connect and disconnect, if they are kept
clean and used correctly. The recommendations listed below must always apply when using flat face quick
release couplings.
Read the correct connecting and releasing procedures before you install or remove any optional attachment
connected with quick release couplings.
Essential do's:
• Before connecting or removing any hydraulic hose, the residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service line has been vented before connecting or removing
the hoses.
• Always wipe the two mating faces clean before connecting.
• Use caps and plugs when the couplings are disconnected.
• Always align the external locking ball (if used) with the notch in the locking sleeve and then pull the locking
sleeve back fully to disconnect.
• If a coupling sticks, first check that pressure has been released. Make sure the locking ball and notch
in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally
caused by dirt in the coupling or physical damage due to abuse.
• Connect and disconnect the new couplings two or three times to work the PTFE seals. Sometimes a new
coupling will stick if the seal has not been worked.
• When connecting the couplings, only apply the spanner or grips to the hexagon and nowhere else.
• Avoid damage to the coupling faces. Burrs and scratches cause damage to the seals and cause leaks.
They can also impede connection and disconnection of the couplings.
• Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.
Essential don'ts:
• Never try to reconnect using a damaged half coupling as this will destroy the seals in the mating half and
necessitate replacement of both halves.
• Do not leave the coupling where it may be run over by a machine or otherwise crushed, this will distort
the sleeve and prevent connection and disconnection.
• Never try to turn the sleeve when the coupling is disconnected as this will cause the locking ball to jam
under the locking sleeve and damage the coupling.
• Never try to strip the coupling down, there are no user serviceable parts. If the coupling is damaged it
must be replaced with a new one.
• Never hit the centre poppet of the coupling to try and release the locked in pressure. This can cause
irreparable damage to the coupling and serious injury.
• When connecting the couplings, never clamp on the sleeve of the female or nose of the male, this will
cause distortion and/or damage.
• Never subject the couplings to external forces, especially side load. This can decrease the life of the
coupling or cause failure.
• Never allow the torsional forces transmitted from the hoses to unscrew/screw together the couplings.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed
to do so.
Connecting Quick Release Couplings

1. Remove any residual hydraulic pressure trapped in the service line hose.
2. Wipe the two faces of the male and female couplings and make sure they are clean.
3. Make sure that ball in the female coupling is located in one of its slots.
112 9831/1850-4 112

Attachments
4. Connect the male coupling into the female coupling.

5. Where applicable, rotate the sleeve half a turn and make sure that the locking ball does not align with
the slot.
Figure 82.
C D E
C Ball D Slot
E Sleeve
Disconnecting Quick Release Couplings

1. Remove any residual hydraulic pressure trapped in the service line hose.
2. Where applicable, align the slot with ball.
3. Pull back the sleeve to release the coupling.
113 9831/1850-4 113

Attachments
Quickhitch
Quickhitch
General
WARNING If two people are doing this job make sure that the person working the controls is a competent
operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could
be killed or injured.
WARNING Do not retract the locking pins when the lift arm is raised, the shovel could fall and kill or seriously
injure someone. Retract the locking pins only after the attachment has been placed on the ground.
Keep other people clear of the area while you engage the attachment. If a second person is to be involved in
this procedure, make sure that they keep clear of the machine and attachment until signalled by you to proceed.
For more information on the servo-control lever and the auxiliary controls
A Quickhitch isolator valve is installed on all machines. This valve can be used to hydraulically operate the
locking pins to lock an attachment to the Quickhitch. The valve is operated by the Quickhitch isolator switch
in the cab.
When the Quickhitch isolator switch is operated at the same time as the auxiliary buttons/lever, hydraulic
pressure is diverted to the locking pins.
• When the locking pins are fully out, they are disengaged.
• When the locking pins are partially out, they are partially engaged.
• When the locking pins are fully in, they are fully engaged.
The red indicators show the position of the pins, the main pins are fully engaged when the red indicators can't
bee seen anymore.
Figure 83.
B
A
A Locking pins B Indicators
Lubricate
Remove the attachments before you grease the locking pins. Total of 2 grease points. Refer to Figure 83.
When working in difficult conditions, grease and operate the locking-pins every 10 hours.
Lift Arm Quickhitch Carriage
114 9831/1850-4 114

Attachments
Quickhitch
Disengage the Attachment

Figure 84.
A
A Locking pins
1. Park the machine on solid, level ground.

2. Engage the park brake and put the transmission in neutral.
2.1. If necessary, disconnect the hydraulic hoses.
3. Push and hold the Quickhitch isolator switch.
4. Disengage the locking pins: Refer to Figure 84.
4.1. Proportional lever control with an auxiliary button: Push the auxiliary button until the locking pins are
retracted.
Figure 85.
D B
A F
E

E Forward/reverse switch F Secondary auxiliary button
4.2. Multi lever control option: Push the lever until the locking pins are retracted.
115 9831/1850-4 115

Attachments
Quickhitch
Figure 86.
A B
C
D
F
G
5. Release the Quickhitch isolator switch.

6. Disengage the attachment:
6.1. Proportional lever control: Move the lever to the right and tilt the Quickhitch forward and lower the
lift arm.
6.2. Multi lever control option: Move the lever forward and tilt the Quickhitch forward and lower the lift arm.
7. When the pivot shaft has disengaged from the hooks, reverse the machine clear.
Figure 87.
A B
A Pivot shaft B Hooks
Engage the Attachment

1. Align the machine square with the attachment.
2. Lower the lift arm until the pivot shaft is below the level of the hooks on the attachment. Refer to Figure 88.
Figure 88.
A B
A Pivot shaft B Hooks
3. Drive the machine slowly forward, stop when the pivot shaft just touches the attachment.
4. Engage the park brake and put the transmission in neutral.
116 9831/1850-4 116

Attachments
Quickhitch
5. Raise the lift arms and engage the pivot shaft into the hooks. Stop the movement as soon as the pivot
shaft is engaged.
6. Engage the attachment:
6.1. Proportional lever control: Move the lever to the left and tilt the Quickhitch fully back.
Figure 89.
D B
A F
E

6.2. Multi lever control option: Move the lever to the rear and tilt the Quickhitch fully back.
Figure 90.
A B
C
D
F
G
7. Engage the locking pins in the attachment:
117 9831/1850-4 117

Attachments
Quickhitch
7.1. Proportional lever control with an auxiliary button: Push the auxiliary button until the locking pins are
engaged.
7.2. Multi lever control option: Push the lever until the locking pins are engaged.
8. Make sure the locking pins in the base of the Quickhitch are fully engaged. Refer to Figure 91.
Figure 91.
A
A Red locking pins
9. Release the Quickhitch isolator switch.

10. If necessary connect the hydraulic hoses.
118 9831/1850-4 118

Attachments
Tow Hitches
Tow Hitches
Hydraulic Tow Hitch
Before using the hydraulic tow hitch you must refer to the important pertinent information. Refer to: Towing
Other Equipment (Page 81).
Before you connect and disconnect the trailer the hydraulic tow hitch must be deployed to working position.
Figure 92.
Working Position
To deploy the hydraulic tow hitch:

2. Check the rear mirror, if necessary adjust the mirror to obtain a good view of the tow hitch area.
3. Before you use the hydraulic tow hitch check the position of it using the rear mirror.
4. Rotate the hydraulic tow hitch fully to the working position.
4.1. Press the hydraulic tow hitch switch to divert 1st auxiliary flow from front chassis to rear chassis. One
indicator light will illuminate. Refer to Figure 92.
4.2. Press and hold the hydraulic tow hitch switch. Two indicator light will illuminate. Refer to Figure 92.
4.3. Operate the auxiliary lever/button on the operating lever to fully rotate the hydraulic hitch. Refer to
Figure 93. , Refer to Figure 94.
119 9831/1850-4 119

Attachments
Tow Hitches
Figure 93. Proportional Control Lever

D B
A F
E

Figure 94. Multi Control Lever

A B C
D
F
G
4.4. Use the rear mirror to check the position of the hydraulic tow hitch.
4.5. When the hydraulic tow hitch is fully deployed (working position) it is visible to the operator in the rear
mirror. Refer to Figure 95.
120 9831/1850-4 120

Attachments
Tow Hitches
Figure 95.
A B
A Stowage position B Working position
4.6. To make sure the hydraulic tow hitch is fully rotated to working position continue to hold the rotate
switch and auxiliary lever/button for time specified until the hydraulic service activates the relief valve.
This will make sure that the rotate ram is fully extended.
Duration: 2 s
4.7. Release the hydraulic tow hitch switch. One indicator light will be illuminated to show that tow hitch
mode is enabled.
4.8. To enable 1st auxiliary hydraulics to front chassis, press the hydraulic tow hitch switch. No indicator
light will be illuminated.
Connecting the Trailer

The trailer hydraulics and hydraulic tow hitch are operated independently of the loader end auxiliaries. You can
operate the trailer hydraulics without having to disconnect and connect the hydraulic feed from the tow hitch.

2. Check the rear mirror, if necessary adjust the mirror to obtain a good view of the tow hitch area.
3. Make sure one indicator light is illuminated on hydraulic tow hitch switch.
4. Fully rotate the hydraulic tow hitch to the working position. Refer to Figure 95.
5. Pull and hold the tow hitch cable to release the locking lever.
Refer to: Operator Station (Page 16).
6. Operate the auxiliary lever/button on the operating lever to lower the hook. Refer to Figure 93.
7. Use the rear mirror to check the position of the hook.
8. Lower the hook to the catch position. Refer to Figure 96.
121 9831/1850-4 121

Attachments
Tow Hitches
Figure 96.
A Hook - lock position B Hook - catch position
9. Engage the trailer.

9.1. Make sure that the trailer and its drawbars are correctly positioned for engagement before the machine
begins to approach it.
9.2. Make sure the trailer tow bar is parallel with the machine when the pickup hitch is raised and locked.
9.3. Make sure the hydraulic tow hitch is correctly aligned with the trailer towing eye.
10. Operate the auxiliary lever/button on the operating lever to raise the hook to the lock position. Refer to
Figure 93.
10.1. If necessary drive the machine forward to prevent the pickup hitch overriding the trailer towing hitch.
11. The tow hitch cable will automatically spring back to the engaged position when the hook is raised.
12. Turn off the hydraulic tow hitch up/down divert switch.
Disconnecting the Trailer

2. Disengage the trailer.
2.1. Make sure the trailer tow bar is parallel with the machine when the pickup hitch is lowered.
2.2. Make sure the hydraulic tow hitch is correctly aligned with the trailer towing eye.
3. Pull and hold the tow hitch cable to release the locking lever.
Refer to: Operator Station (Page 16).
4. Make sure one indicator light is illuminated on hydraulic tow hitch switch.
5. Operate the auxiliary lever/button on the operating lever to lower the hook. Refer to Figure 93.
6. Use the rear mirror to check the position of the hook.
7. Lower the hook to the catch position. Refer to Figure 96.
8. When the trailer has been disengaged, raise the hook to the lock position. Refer to Figure 96.
122 9831/1850-4 122

Attachments
Tow Hitches
9. Move the machine away from trailer. The tow hitch cable will automatically spring back to the engaged
position when the hook is raised.
10. Rotate the hydraulic tow hitch to stowage position. Refer to Figure 95.
11. Press the hydraulic tow hitch switch to return 1st auxiliary flow to front chassis. No indicator lights will be
illuminated.
Stowage Position
When the hydraulic tow hitch is not in use make sure it is always in stowage position.
To stow the hydraulic tow hitch:

2. Before you use the hydraulic tow hitch check the position of it using the rear mirror.
3. Fully rotate the hydraulic tow hitch to the stowage position.
3.1. Press the hydraulic tow hitch switch to divert 1st auxiliary flow from front chassis to rear chassis.
3.2. Press and hold hydraulic tow hitch the switch.
3.3. Operate the auxiliary lever/button on the operating lever to rotate the hydraulic hitch. Refer to Figure
93.
3.4. Use the rear mirror to check the position of the hydraulic tow hitch.
3.5. Make sure the hydraulic tow hitch is fully stowed. Refer to Figure 95.
3.6. To make sure the hydraulic tow hitch is fully rotated to stowage position continue to hold the hydraulic
toe hitch switch and auxiliary lever/button for time specified until the hydraulic service activates the
relief valve. This will make sure that the rotate ram is fully retracted.
Duration: 2 s
Preparing the Trailer for Towing

Figure 97.
A B
A Electrical socket B Trailer brake socket

C Trailer auxiliary hose socket
1. Connect the trailer lights into socket. Refer to Figure 97.

Refer to: Relays (Page 193).
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Attachments
Tow Hitches
2. Make sure that all the trailer lights and the direction indicator lights are working correctly and are visible
by other road users.
3. If an optional trailer brake valve is installed, connect the trailer brakes into socket. Trailer braking is operated
by the brake pedals. Refer to Figure 97.
4. Before you travel on the public highway, check that the brakes work correctly and get used to the braking
effect.
5. To operate trailer auxiliary services:
5.1. Connect the trailer auxiliary hose to the socket. Refer to Figure 97.
5.2. Press the auxiliary switch to divert auxiliary flow at the 3rd spool from front chassis to rear chassis.
6. For the trailer auxiliary operation, operate the switch depending on the attachment installed and the function
required.
7. To prevent contamination of the machine hydraulics, close all rams on the attachment/trailer before
disconnecting the hydraulic service to exhaust the trailer ram.
Maintenance
Grease Points
All grease points must be checked daily. Refer to: Maintenance Schedules (Page 140). Refer to: Fluids,
Lubricants and Capacities (Page 207).
Figure 98.
A Grease nipple points - daily check B Grease all four sides of the tow hitch leg - daily
check.
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Attachments
Work Platforms
Work Platforms
General
DANGER Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured.
Never use the forks as a working platform.
The use of work platforms with this machine is subject to legislation which varies from territory to territory. It is
the responsibility of the owner/operator and supplier of the work platform to ensure compliance with the relevant
legislation in the relevant territory. In the case of uncertainty, guidance should be sought from the relevant local
or government authority.
JCB supply integrated work platforms solely for use in Europe which comply with the requirements of European
Directive 2006/42/EC. Contact your dealer for further details. Health and safety legislation also varies from
territory to territory. Customers should check the latest health and safety legislation for the territory in which
the work platform is to be used prior to operation.
125 9831/1850-4 125

Notes:
126 9831/1850-4 126

Cleaning

Cleaning
General
WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's
instructions and safety precautions.
WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must
not be allowed to accumulate within the engine compartment or in the propshaft guards (when installed).
Examine these areas frequently and clean at the beginning of each work shift or more often if required.
Before opening the engine cover, make sure that the top is clear of debris.
CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect
your eyes, wear goggles when using a brush to clean components.
Notice: Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning
agents and solvents.
Notice: The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from
around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the
risk of weather corrosion.
Notice: Never use water or steam to clean inside the operator station. The use of water or steam could
damage the machine electrics and render the machine inoperable. Remove dirt using a brush or damp cloth.
Clean the machine with water and/or steam. Do not let mud, debris etc. to collect on the machine.
Before you do any service procedures that require components to be removed:
• The cleaning must be done either in the area of components to be removed, or in the case of major work,
or work on the fuel system, the whole engine and the surrounding machine must be cleaned.
• When cleaning is complete, move the machine away from the wash area or alternatively, remove the
material washed from the machine.
When you remove components, be aware of exposure to dirt and debris. Cover any open ports and remove
the deposits before proceeding.
Refer to the individual clean procedures throughout the Maintenance section. Refer to: Maintenance Schedules
(Page 140).
Detergents
Do not use a full strength detergent. Always dilute the detergents as per the manufacturer's recommendations,
or damage to the paint finish can occur.
Always obey the local regulations regarding the disposal of debris created from cleaning the machine.
Pressure Washing and Steam Cleaning

CAUTION When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing.
Steam can cause personal injury.
Notice: The engine and other components could be damaged by high pressure washing systems. Special
precautions must be taken if the machine is to be washed using a high pressure system.
Make sure that the alternator, starter motor and any other electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or
the engine air induction system.
Use a low pressure water jet and brush to remove dried mud or dirt.
Use a pressure washer to remove soft dirt and oil.
The machine must always be greased (if appropriate) after pressure washing or steam cleaning.
127 9831/1850-4 127

Cleaning
Preparation
2. Stop the engine and let it cool for at least one hour. Do not try to clean any part of the engine while it is
running.
3. Make sure that all of the electrical connectors are correctly coupled. If the connectors are open, attach the
correct caps or seal with water proof tape.
128 9831/1850-4 128

Checking For Damage
Checking For Damage

General
Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance Schedules
(Page 140).
129 9831/1850-4 129

Storage
Storage
General
If the machine will not be used for an extended period, you must store the machine correctly. If you prepare
the machine carefully and apply on-going care you can prevent deterioration and damage to the machine while
it is in storage.
Storage Area
The machine can be stored in a temperature range of: -40 °C ( -39.9 °F) to 54 °C ( 129.1 °F)
When possible, you must keep the machine in a dry building or shelter.
If only an outdoor storage area is available, look for a storage area with good drainage.
Prepare the Machine for Storage

1. Clean the machine to remove all unwanted material and corrosive products.
2. Dry the machine to remove solvents and moisture.
3. Touch-up any damaged paint.
4. Apply grease to the moving parts (if applicable).
5. Examine the machine for worn or damaged parts. Replace if necessary.
6. Fill the fuel tank to prevent a build up of condensation in the tank (if applicable).
7. Examine the coolant condition. Replace if necessary.
8. Examine all fluid levels. Top up if necessary.
Put into Storage

1.1. Park the machine in an area where it is easy to access. (In case the machine does not start at the
end of the storage period).
1.2. Put suitable timbers under the machine to eliminate direct contact with the ground.
2. Retract all of the rams and lower the attachment to the ground.
4. Remove the ignition key.
5. Apply a thin layer of grease or petroleum jelly to all of the exposed ram piston rods.
6. Remove the battery.
6.1. Keep the battery in warm, dry conditions.
6.2. Charge the battery periodically.
7. If you keep the machine outdoors, cover the machine with tarpaulins or plastic sheets.
During Storage
Operate the machine functions each week to prevent a build up of rust in the engine and hydraulic circuits, and
to minimise the deterioration of the hydraulic seals.
1. Remove the grease or petroleum jelly from the ram piston rods.
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Storage
2. Examine all fluid levels. If necessary, add more fuel and DEF (Diesel Exhaust Fluid).
3. Install a charged battery.
5. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.
6. Prepare the machine for storage.
Effects of Storage on the DEF System (if applicable)

If the engine has been shutdown correctly and there are no faults with the DEF system, the DEF system and
engine can remain in a deactivated state under the following conditions:
Table 28.
Storage Period Storage Actions
Up to 9 months Fill DEF tank to maximum level with fresh DEF. Do
not disconnect any electrical or hydraulic connec-
tions. Make sure the ambient temperature is between
-40 –30 °C ( -39.9 –86.0 °F)
Longer than 9 months Carry out recommissioning process
Take out of Storage

1. Examine the coolant condition. Replace if necessary.
2. Examine all fluid levels. If necessary, add more fluid.
3. Clean the machine to remove all unwanted material and corrosive products. Dry the machine to remove
solvents and moisture.
4. Remove the grease or petroleum jelly from the ram piston rods.
5. Install a charged battery.
7. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly.
DEF Recommissioning Process (if applicable)

1. Drain the DEF (Diesel Exhaust Fluid) tank.
2. Refill DEF tank with fresh fluid.
3. If a DEF system failure is detected, contact your JCB dealer for advice.
131 9831/1850-4 131

Security
Security
General
Vandalism and the theft of unattended machines is an ever increasing problem and JCB is doing everything
possible to help stop this.
Your JCB dealer will be pleased to provide information on any of these sensible precautions. Act now!
JCB Plantguard
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 etc.
Remember that the installation 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 help to reduce insurance premiums.
Construction Equipment Security and Registration Scheme (CESAR)
CESAR (Construction Equipment Security and Registration) is a simple, effective method of machine
identification and registration that operates throughout the United Kingdom and Ireland and across the whole
spectrum of JCB products.
CESAR is a scheme to help decrease plant theft, and was developed by the Metropolitan Police and the Home
Office Plant Theft Action Group.
The key to the scheme is its simplicity and it will mean that every police officer in the country will know how to
identify construction machinery and verify ownership. This will provide a major leap forward in both protecting
machinery, and recovering it.
The Construction Equipment Association is managing the scheme, and Datatag are providing the security
material and support. JCB is fully supportive of the CESAR initiative and will offer it as a factory option across
the range.
The CESAR kit includes 2 tamper proof triangular identification plates installed on either side of the machine,
a unique transponder, mini radio frequency identification tags concealed throughout the machine, Datatag
micro dots, and a unique DNA coded chemical painted on the machines major components. Plus a registration
certificate logged onto the CESAR or DVLA databases, and a change of keeper form.
LiveLink
Your JCB machine may be installed with LiveLink, JCB's advanced machine monitoring system. LiveLink
monitors a range of information about your machine and sends it through cellular and satellite communication
back to JCB's secure monitoring centre.
The machine owners and JCB dealers can then view that information through the LiveLink website, by email
and even through text message. If you want to know how LiveLink can help manage your JCB machines,
contact your local dealer for more information.
132 9831/1850-4 132

Maintenance
Introduction
Maintenance
Introduction
General
Your machine has been designed and built to give maximum performance, economy and ease of use under
a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the factory and
by your dealer to make sure that it reaches you in optimum condition. To maintain this condition and trouble
free operation it is important that the routine services and maintenance, as specified in this manual, are done
at the recommended specified intervals and it is recommended that this is done by an approved JCB dealer
using genuine JCB parts. Servicing/repairs carried out by unauthorised personnel or the use of non-genuine
inferior quality parts could limit machine warranty.
After completing any routine servicing, maintenance or repairs you must complete the functional checks
according to the maintenance schedule.
This section of the manual gives full details of the service requirements necessary to maintain your JCB
machine at peak efficiency.
It can be seen from the service schedules on the following pages that many essential service checks must only
be done by a JCB trained specialist competent person. JCB dealer service engineers have been trained by
JCB to do such specialist tasks, and are equipped with the necessary special tools and test equipment to do
such tasks, thoroughly, safely, accurately and efficiently.
JCB regularly updates its dealers to advise them of any machine developments, changes in specifications and
procedures. Therefore only a JCB dealer is fully able which makes them best placed to maintain and service
your machine.
A service record sheet or book is provided at the back of this publication which will enable you to plan your
service requirements and keep a service history record. It must be dated, signed and stamped by your dealer
each time your machine is serviced.
Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its
resale value will be greatly enhanced.
When the machine is removed from service, local regulations for machine decommissioning and disposal will
vary. Contact your nearest JCB dealer for further information.
Owner/Operator Support
JCB together with your dealer wants you to be completely satisfied with your new JCB machine. However, if
you do have a problem, you can contact your dealers service department who are there to help you!
You will have been given the names of the relevant service contacts at your dealer when the machine was
supplied.
To get the most from your dealer please help them to satisfy you by providing them with:
1. Your name, address and telephone number.

2. Your machine model and serial number.
3. The date of purchase and hours of work.
4. The nature of the problem.
Remember, only your JCB dealer has access to the vast resources available at JCB to help support you. In
addition, your dealer is able to offer a variety of programmes covering warranty, fixed price servicing, safety
inspections, including weight tests, covering both legal and insurance requirements.
133 9831/1850-4 133

Maintenance
Introduction
Service/Maintenance Agreements
To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage
of the many service and maintenance agreements your dealer can offer. These can be tailor made to meet
your operating conditions, work schedule etc.
Please consult your JCB dealer for details.
Initial Service and Inspection

To further protect your machine's performance it is essential your JCB distributor carries out an initial service
and inspection when the machine is one month old or when it has completed 100 h of operation (whichever
occurs first). You should notify your distributor in advance to allow the necessary arrangements to be made.
Obtaining Spare Parts

If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the
operator and cause machine failure.
A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts
and order them from your JCB dealer.
Your dealer will need to know the exact model, build and serial number of your machine. Refer to: Product and
Component Identification (Page 10).
The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable.
Remember, if any of these units have been changed, the serial number on the data plate may be wrong. Check
on the unit itself.
134 9831/1850-4 134

Maintenance
Maintenance Safety
Maintenance Safety
General
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Air Conditioning Maintenance
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system
should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained
person. You can be severely frostbitten or injured by escaping refrigerant.
Compressed Air
Compressed air is dangerous. Wear personal protective equipment. Never point a compressed air jet at yourself
or others.
Springs
Always wear personal protective equipment when dismantling assemblies containing components under
pressure from springs. This will protect against eye injury from components accidentally flying out.
Metal Splinters
You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or
copper drift to remove and install metal pins. Always wear personal protective equipment.
Communications
Bad communications can cause accidents. If two or more people are working on the machine, make sure each
is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger
areas. Examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages,
and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.
Repairs
If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary
repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance
work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual
hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been
vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.
'O' rings, Seals and Gaskets
Badly installed, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near
'O' rings and seals.
Arc Welding
To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before
arc-welding on the machine or attached implements.
If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units
(ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive
electrical equipment could result in irreparable damage to these components.
Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not
weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage
to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being
welded no more than 0.6 m.
Counterweights
Your machine may be installed with counterweights. They are extremely heavy. Do not attempt to remove them.
135 9831/1850-4 135

Maintenance
Maintenance Safety
Accumulators
The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on
systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden
release of the hydraulic fluid or gas may cause serious injury or death.
Hot Components
Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been
running. Allow the engine and components to cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work under a machine on soft ground.
Working Under the Machine
Make the machine safe before getting beneath it. Make sure that any attachments on the machine are correctly
attached. Engage the park brake, remove the ignition key, disconnect the battery. If the machine has wheels
use blocks to prevent unintentional movement.
Lifting the Machine
Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked
clear of the ground, since the wheel on the ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials
such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can
produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components
at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose
temperatures have not exceeded 300 °C ( 571.6 °F) require no special safety precautions. If evidence
of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions. Do not touch
component or surrounding area. Used fluoroelastomeric components subjected to temperatures greater than
300 °C ( 571.6 °F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that
heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium
hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water. 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
fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment before performing maintenance on the machine, otherwise
you could be injured.
Working at Height
Use appropriate access equipment such as ladders or a working platform if it is necessary to work at height
to perform maintenance tasks on the machine. If you do not use suitable access equipment there is a risk of
falling, resulting in personal injury or death.
Fluids and Lubricants

Oil
Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use
barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy
water. Do not use petrol, diesel fuel or paraffin to clean your skin.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure
and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks and then examine
the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
136 9831/1850-4 136

Maintenance
Maintenance Safety
Fuel
Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is
suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running.
Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow
these precautions.
Hygiene
JCB lubricants are not a health risk when used correctly for their intended purposes.
However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness
and irritation.
Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you must maintain good standards of care and personal and plant
hygiene. For details of these precautions we advise you to read the relevant publications issued by your local
health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
CAUTION Damaged or spent batteries and any residue from fires or spillage must be put in a suitable
closed receptacle and must be disposed of in accordance with local environmental waste regulations.
All waste products must be disposed of in accordance with all the relevant regulations.
The collection and disposal of used oil must be in accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground.
Handling
CAUTION The temperature of the hydraulic oil will be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
New Oil
There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene
practices.
Used Oil
Used engine crankcase lubricants contain harmful contaminants.
Here are precautions to protect your health when handling used engine oil:
• Avoid prolonged, excessive or repeated skin contact with used oil

• Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil
from skin:
• Wash your skin thoroughly with soap and water
137 9831/1850-4 137

Maintenance
Maintenance Safety
• Using a nail brush will help

• Use special hand cleansers to help clean dirty hands
• Never use petrol, diesel fuel, or paraffin for washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
• Throw away oil-soaked shoes
Battery
Warning Symbols
The following warning symbols may be found on the battery.
Figure 99.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil

Eyes
In the case of eye contact, flush with water for 15min. If irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical advice.
Skin
In the case of excessive skin contact, wash with soap and water.
Spillage
Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical
disposal area.
Fires
WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam.
First Aid - Electrolyte

Eyes
In the case of eye contact, flush with water for 15 min. always get medical attention.
138 9831/1850-4 138

Maintenance
Maintenance Safety
Swallowing
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
Skin
Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.
First Aid - DEF (if applicable)

Do not drink or inhale DEF (Diesel Exhaust Fluid). If large quantities of DEF have been swallowed a doctor
should be called immediately. Do not induce vomiting unless directed to do so by medical personnel. Never
give anything by mouth to an unconscious person.
Avoid prolonged or repeated skin contact. After contact with skin wash thoroughly with plenty of soap and
water. If irritation develops seek medical advice.
Avoid contact with eyes, skin and clothing. Wear chemical resistant gloves, overalls and safety goggles
complying with an approved standard. If in contact with eyes, rinse immediately with plenty of clean water. If
irritation occurs seek medical attention. Always wash hands and arms thoroughly after handling before eating,
drinking, smoking or using the lavatory.
139 9831/1850-4 139

Maintenance
General
WARNING Maintenance must be done only by suitably qualified and competent persons.
Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level
ground.
To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the
battery isolator if installed) when you are not using electrical power. If you do not take these precautions
you could be killed or injured.
A badly maintained machine is a danger to the operator and the people working around the operator. Make
sure that the regular maintenance and lubrication tasks listed in the service schedules are done to keep the
machine in a safe and efficient working condition.
To ensure the correct functioning of the engine and emissions control system all operation and maintenance
must be conducted in accordance with the instructions in this manual. Incorrect operation, maintenance or
repair of the engine and emissions control system may lead to reduced product life, loss of performance
or malfunctions. It is the machine owner's responsibility to ensure maintenance is conducted properly in
accordance with the requirements in this manual.
Apart from the daily tasks, the schedules are based on the machine running hours. Keep a regular check on
the hourmeter readings to correctly gauge the service intervals. When there is no hourmeter installed, use the
calendar equivalents to determine the service intervals.
Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance
checks are corrected immediately.
More frequent checks of engine components than the engine manufacturer recommends do not invalidate
emissions warranty.
How to Use the Maintenance Schedules

The schedules show the service tasks which must be done and their intervals.
The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first.
The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions
(high temperature, dust, water, etc.) shorten the intervals.
Table 29.
Service task can be completed by a competent operator. Details of how to com-
plete the service task are given in the Operator's Manual.
We recommend that a Service Engineer completes the service task. Details of
how to complete the service task are given in the Service Manual.
Maintenance Intervals
General
Table 30.
Interval ( h) Calendar Equivalent
10 Daily
50 Weekly
100 Monthly
500 6 months
1000 Yearly
140 9831/1850-4 140

Maintenance
Interval ( h) Calendar Equivalent

2000 2 Years
8000 8 Years
Pre-start Cold Checks, Service Points and Fluid Levels
Table 31.
Operation 10 50 100 100 500 1,000 2,000
(1)
Attachments
Hydraulic tow hitch Check (operation)
Hydraulic tow hitch Check (condition)
Hydraulic tow hitch Grease
Engine
Oil level Check
Oil and filter
(2)
Change
Coolant Change
Coolant Level
(13)
Check
Coolant strength and condition Check
CCV (Crankcase Ventilation) Change
filter (if installed)
(3)
Air cleaner outer element

(4)
Change
Air cleaner cover/duct
(4)
Clear
Air cleaner scavange hose
(4)
Clear
Air cleaner inner element Change
Fuel system for leaks and con- Check
tamination
Fuel filter Change
Fuel sedimenter/water separa- Drain
tor
Fuel sedimenter/water sepa- Change
rater
Fan belt condition
(5)
Check
Valve clearances Check/adjust
External oil leaks Check
Radiator Clean
All hoses for condition and se- Check
curity
Rocker cover and injector Check
seals
(6)
High pressure fuel lines

(7)
Check
Transmission and Axles
Transmission oil level Check
Differential oil level Check
Differential oil
(8)
Change
141 9831/1850-4 141

Maintenance
Operation 10 50 100 100 500 1,000 2,000

(1)
Hub oil level Check

Hub oil Change
Axle breathers Clean
Tyre pressures and condition Check
Wheel nut security Check
Axle mount security Check
Driveshaft security Check
Driveshaft and universal Grease
joints
(9)
Transmission mount security Check

Transmission oil and filter Change
Hydraulics
Oil level Check
Oil filter Change
Oil Change / Sample
Tank suction strainers Change
Hoses, rams and pipework for Check
damage and leaks
Aftertreatment
DEF (Diesel Exhaust Fluid) Change
supply module filter
(2)
DEF tank cap

(2)
Check
DEF tank neck filter Check (condi-
tion)/Clean
Brakes
Park brake operation Check
Service brake operation Check
Electrics
Instrument panel operation Check
Battery electrolyte level (if ap- Check
plicable)
Battery charge and condition Check
Battery terminals condition and Check
tightness
Wiring for chafing and routing Check
Bodywork and Cab
Machine condition - general Check
Wing mirrors condition and se- Check
curity
Autolube reservoir level (if in- Check
stalled)
(10)
Autolube resevoir filler filter (if Check

installed)
(10)
142 9831/1850-4 142

Maintenance
Operation 10 50 100 100 500 1,000 2,000

(1)
All pivot pins

(11)
Lubricate
Steer rams
(11)
Lubricate
Quickhitch locking pins
(11)
Lubricate
Window washer fluid level
(13)
Check
Cab heater intake filter(s)
(4)
Clean
Seat belt condition and securi- Check
ty
Hinges Lubricate
ROPS (Roll-Over Protective Check
Structure)/FOPS (Falling Ob-
ject Protective Structure) struc-
ture
Lifting Equipment
Fit for purpose test
(12)
Complete
(1) First 100 hours service only, to be completed by your JCB distributor
(2) In arduous conditions, change the engine oil and filter after every 250 hours or three months (whichever
comes first)
(3) Change at 1500 hours and then each subsequent 1500 hours
(4) More frequently if operating in dusty environments
(5) Change if necessary
(6) Change the injectors and leak off rails every 6000 hours
(7) Check every 6000 hours
(8) At the first 500 hours then every 1000 hours
(9) Grease more frequently in arduous conditions
(10) Top-up as Necessary
(11) Grease every 10 hours when operating in arduous conditions
(12) This may be required every 6 months or at least annually in some countries to meet and comply with
legislation and for insurance purposes
(13) In cab check
Functional Tests and Final Inspection

Table 32.
Operation 10 50 100 500 1,000 2,000
(1)
Engine
Idle speed Check/adjust
Maximum no load speed Check/adjust
Exhaust smoke (excessive) Check
Exhaust aftertreatment system secu- Check
rity
Air inlet system security Check
Crankcase breather Check
Transmission, Axles and Steering
Transmission operation Check
Transmission calibration Check/Adjust
Forward/reverse/speed range opera- Check
tion
143 9831/1850-4 143

Maintenance
Operation 10 50 100 500 1,000 2,000

(1)
Neutral start operation Check

Steering operation Check
Hydraulics
Operation of all services Check
Hose burst protection valves (If in- Check
stalled)
MRV (Main Relief Valve) pressure Check/adjust
ARV (Auxiliary Relief Valve) pressure Check(2)
Steer circuit MRV pressure Check/adjust
Ram rods condition Check
Electrics
Fault codes/datalogger history Check
Gauges and warning lights Check
Wiper motors Check
Cab switches operation Check
Horn Check
Heater (if installed) Check
Reverse alarm (if installed) Check
Lights and Indicators (if installed) Check
Starter motor connections Check
Alternator connections Check
Bodywork and Cab
Glazing for correct fit Check
Doors and hinges Check
Toolkit and handbook Check
Locks and keys Check
Air-conditioning (if installed) Check
Generally for damage, leaks and Check
Wear (include the ROPS (Roll-Over
Protective Structure) and FOPS
(Falling Object Protective Structure))
Paintwork condition Check
Check for fluid leaks, (for example Check
engine oil, hydraulic oil)
Attachments
Attachment condition and operation Check
(1) First 100 hours service only, to be completed by your JCB distributor
(2) ARV's are non-adjustable. Any ARV found to be outside the specified values as stated in Technical Data
will need to be replaced. Details on the correct procedure can be found in the relevant section of this manual
144 9831/1850-4 144

Maintenance
General
Communications
Bad communications can cause accidents. If two or more people are working on the machine, make sure each
is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger
areas. Examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages,
and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.
WARNING! Maintenance must be done only by suitably qualified and competent persons. Before doing any
maintenance make sure the machine is safe, it must be correctly parked on solid, level ground. To prevent
anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator
if installed) when you are not using electrical power. If you do not take these precautions you could be killed
or injured.
WARNING! Make the machine safe before getting beneath it. Make sure that any attachments on the machine
are correctly attached. Engage the park brake, remove the ignition key, disconnect the battery.
Make the machine safe before you start a maintenance procedure.
You can complete most of the maintenance procedures with the lift arm lowered. Unless a maintenance
procedure instructs you differently, you must lower the lift arm.
Maintenance Position (Lift Arm Lowered)

Figure 100.
Lift arm lowered
1. If necessary, empty the shovel.

2. Make sure that the machine is parked correctly in the straight-ahead position on solid, level ground.
3. Lower the lift and put the attachment flat on the ground.
4. Stop the engine and remove the ignition key.
5. Put chocks on both sides of all the wheels.
6. Remove the battery isolation key.
7. Install the articulation lock.
8. Operate the controls to release the residual pressure.
9. If you are working on an area that you can not reach when standing on the ground, you must use a suitable,
safe work-platform.
145 9831/1850-4 145

Maintenance
Maintenance Position (Lift Arm Raised)

Figure 101.
Lift arm raised
If you must raise the lift arm to get access to perform non-routine maintenance procedure lift arm support
devices must be used.
Lift arm support devices are supplied with a machine as an option and your machine may not be equipped
with them. Do not attempt to carry out maintenance operations beneath a raised lift arm unless you use the
correct lift arm support devices.
Install the Maintenance Struts (If Supplied)

1. If necessary, empty the shovel.
2. Make sure that the machine is parked correctly in the straight-ahead position on solid, level ground.
3. Raise the lift arm sufficiently to install the maintenance struts.
4. Run the engine at idle for a few minutes to let the turbo-charger cool.
6. Put chocks on both sides of all the wheels.
8. Remove the maintenance struts from their stowage position.
9. Put a maintenance strut in position around the ram on one side of the machine and lock the strut in position
with the strap.
10. Put the other maintenance strut in position around the ram on the other side of the machine and lock the
strut in position with the strap
12. Slowly lower the lift arm onto the maintenance struts. Stop the movement immediately when the
maintenance struts support the weight of the lift arm.
14. Remove the battery isolation key.
146 9831/1850-4 146

Maintenance

Figure 102.
A B C D
A Strut (one of two) B Strap

C Strap D Strut (two of two)
Stow the Maintenance Struts

1. Engage the park brake. Make sure that the transmission is in neutral.
2. Install the battery isolation key.
4. Raise the lift arm sufficiently to remove the weight from the maintenance struts.
5. Stop the engine.
6. Remove the strap from one of the maintenance struts and remove the strut.
7. Remove the strap from the other maintenance strut and remove the strut.
8. Put the maintenance struts in their stowage position.
9. Remove the articulation lock.
10. Remove the chocks on both sides of all the wheels.
147 9831/1850-4 147

Maintenance
Service Points
Service Points
General
Figure 103.
A
B D
E
C G
A Air filter assembly B Engine oil filter
C Water Separator D Engine oil filler point
E Hydraulic oil filler point F Engine oil dipstick
G Fuel filter H Hydraulic oil level sight glass
Figure 104.
F
A
C D
A Transmission oil filler point B Transmission oil level sight glass

C Window washer fluid D DEF (Diesel Exhaust Fluid) tank filler point
(blue)
148 9831/1850-4 148

Maintenance
Service Points
E Engine coolant expansion tank F Fuel filler point
149 9831/1850-4 149

Maintenance
Access Apertures
Access Apertures
General
When moved to their maintenance position, the access panels give you access to parts or areas of the machine
that are not required during machine operation.
Before you operate the machine, make sure that all of the access panels are correctly in their closed or installed
positions.
Battery Cover
2. If necessary, unlock and remove the lock from the battery compartment latch.
3. Carefully lift the battery compartment cover/steps off the latch and lower to the required position.
3.1. The cover can be latched halfway down on the brackets or fully lowered.
4. To close the cover, reverse the procedure.
Figure 105.
A
A Battery compartment latch B Bracket

C Battery compartment cover/steps
Engine Compartment Cover

WARNING The engine has exposed rotating parts. Switch off the engine before working in the engine
compartment. Do not use the machine with the engine cover open.
Open
Before you stop the engine, you must let the engine run at low idle for 4 min. The delay lets the coolant
temperatures stabilise before you open the engine cover.

2. Unlock the security lock in the release button to open it.
3. Allow the cover to open with the assistance of the gas struts.
Close
1. Pull down the engine cover until the latch engages.
150 9831/1850-4 150

Maintenance
Access Apertures
2. Make sure the cover is securely latched.

3. Lock the security lock and remove the key.
Figure 106.
A
A Engine cover B Release button
Cab Heater Door
Open the heater door:

2. Unlock and press the catch.
Close the heater door:
1. Close the heater door on the area surrounding the catch.

2. Make sure the heater door is latched.
3. Lock the catch.
151 9831/1850-4 151

Maintenance
Access Apertures
Figure 107.
A Cab heater door B Catch
152 9831/1850-4 152

Maintenance
Tools
Tools
General
All tools must be kept in the toolbox (if installed) when not in use.
Toolbox
The location of the toolbox may vary depending on your machines specification. On machines with an auxiliary
fuel tank, the toolbox location is changed.
Keep the tools in the toolbox unless you need to use them.
We recommend that lock the toolbox to prevent theft or tampering.
Figure 108.
A Toolbox
153 9831/1850-4 153

Maintenance
Lubrication
Lubrication
General
CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying
Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.
Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.
You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the
machine's working life.
Refer to the individual condition checks throughout the Maintenance section.
The machine must always be greased after pressure washing or steam cleaning.
Greasing must be done with a grease gun. Normally, two strokes of the grease gun is sufficient. Stop greasing
when fresh grease appears at the joint.
Use only the recommended type of grease. Do not mix different types of grease, keep them separate.
Attach the dust caps after greasing (if installed).
Preparation
WARNING You will be working close into the machine for these jobs. Lower the attachments. Remove
ignition key and disconnect the battery. This will prevent the engine being started.
Make the machine safe before you start a greasing procedure. Refer to: Maintenance Positions (Page 145).
Daily and weekly routine maintenance requirements including greasing procedures can be completed with the
lift arm lowered.
Machine servicing requiring access beneath raised lift arms, should be conducted by a Service Engineer
following instructions provided in the Service Manual and will require the installation of maintenance struts on
the lift arm.
Automatic Greasing System

Automatic Greasing System (if installed)
The following points are greased by the automatic greasing system (when fitted):
• Shovel pivot pins

• Lift arm pivot points
• Centre pivot and steering rams
All other grease points must continue to be greased as per the service schedules.
When the ignition is on, the greasing system performs all operations automatically.
When the ignition is on, the system will default to normal duty mode. For normal operation, this is the required
mode. When working in arduous conditions, heavy duty mode should be selected.
154 9831/1850-4 154

Maintenance
Lubrication
Figure 109. System controls
E
T WIN
Automatic
Greasing
System
GREASING
MODE
F
A Low level lamp (yellow). Reservoir requires B Error lamp (red). System not operating because
replenishing of insufficient grease
C Light duty greasing mode (green). Long interval D Normal duty greasing mode (green). Standard
between grease cycles interval between grease cycles
E Heavy duty greasing cycle (green). Short F Greasing mode selection switch. Press the
interval between grease cycles mode switch until the desired mode lamp
illuminates
155 9831/1850-4 155

Maintenance
Attachments
Attachments
General
Lubricate
Where applicable, refer to the specific manufacturers manual for instructions on the lubrication of optional
attachments.
Check (Condition)
Where applicable, refer to the specific manufacturers manual for instructions on the maintenance of optional
attachments.
156 9831/1850-4 156

Maintenance
Body and Framework
Body and Framework

General
Clean
Thoroughly dry the piston rams and protect them with clean transmission or hydraulic oil if necessary.
Check (Condition)
1. Make sure that all of the guards and protective devices are in position, secured by their locking devices
and free from damage.
2. Inspect all of the steelwork for damage. Include the following:
2.1. Examine all of the pivot point welds.
2.2. Examine the condition of all the pivot pins.
2.3. Check that the pivot pins are correctly in position and secured by their locking devices.
3. Check the steps and handrails are undamaged and correctly attached.
4. Check for broken, cracked or crazed window glass and mirrors. Replace the damaged items.
5. Check that the lamp lenses are undamaged.
6. Check that all of the safety and instructional labels are undamaged and in position. Install new labels where
necessary.
7. Note any damaged paintwork for future repair.
8. Inspect the machine for broken or loose fasteners.
157 9831/1850-4 157

Maintenance
Lift Arm
Lift Arm
General
Lubricate
Shovel and Interlever Pivot-Pins: Total of 8 grease points. (1 to 8).
Loader Arm Pivot Points: Total of 16 grease points (9 to 24).
Figure 110.
When working in difficult conditions, grease and operate the locking-pins every 10 h.
158 9831/1850-4 158

Maintenance
Operator Station
Operator Station
General
Clean
Notice: Never use water or steam to clean inside the operator station. The use of water or steam could
damage the machine electrics and render the machine inoperable. Remove dirt using a brush or damp cloth.
Remove debris and loose articles from inside the cab.
Operator Protective Structure

Check (Condition)
WARNING You could be killed or seriously injured if you operate a machine with a damaged or missing
ROPS/FOPS/FOGS. If the ROPS/FOPS/FOGS has been in an accident, do not use the machine until the
structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS/FOPS/FOGS certification.
A failure to adhere to these precautions can cause death or injury to the operator. For assistance, contact your
JCB dealer.

2. Check the structure for damage.
3. Make sure that all of the ROPS/FOPS mounting bolts are undamaged and in position.
4. Make sure that the ROPS/FOPS mounting bolts are tightened to the correct torque setting.
Refer to: Torque Values (Page 216).
Seat
Check (Condition)
1. Check that the seat adjustments operate correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged, correctly installed and tight.
4. Make sure the seat is clear from unwanted materials and hazards at all times.
Seat Belt
Check (Condition)
WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the
fabric is worn, or if the machine has been in an accident.
WARNING If the seat belt does not 'lock' when you check if the seat belt is operating correctly, do not drive
the machine. Get the seat belt repaired or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and stretching.
3. Check that the stitching is not loose or damaged.
159 9831/1850-4 159

Maintenance
Operator Station
4. Check that the belt mounting bolts are undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged and operates correctly.
Controls
Check (Operation)
Check the operation of the non-hydraulic and non-electrical operator station controls.
160 9831/1850-4 160

Maintenance

Air-Conditioning
Clean
Cab Recirculation Filter

The filter may be filled with dust. Wear goggles and a face mask when you remove the filter.

2. Remove the fasteners, then the grille.
3. Remove the re-circulation filter.
4. Shake the filter to remove the loose dust. Clean the filter with a low pressure jet of compressed air.
5. Keep the filter and grille in position, then install the fasteners.
6. Secure the grille.
Figure 111.
B A B
A Grille B Fasteners
Heater
Clean
The filter may be filled with dust. Wear goggles and a face mask when removing the filter.

2. To get access to the cab heater filter, open the heater door.
Refer to: Cab Heater Door (Page 151).
3. Open the fasteners and remove the cover.
4. Remove the filter from its housing.
5. Shake out the loose dust and clean using low pressure compressed air.
6. Replace the filter if severely blocked or the element is damaged.
161 9831/1850-4 161

Maintenance
7. Install the filter, An additional filter might be installed behind the filter, if applicable, remove filter by pulling
tag provided. Magnetic strips hold the filter in place. Install the filter to make sure it is located correctly.
8. Close the heater door.
Figure 112.
A B C A
A Fasteners B Filter cover
C Filter
162 9831/1850-4 162

Maintenance
Engine
Engine
General
Check (Condition)
Start the engine and check for:
• Excessive smoke
• Excessive vibration
• Excessive noise
• Overheating
• Performance
• Unusual smells.
Oil
Check (Leaks)
Before you start the machine, do a check for oil leaks:

2. Get access to the engine compartment (if applicable)
3. Check the engine and the area below for oil leaks.
4. Close the engine cover (if applicable).
5. If necessary, contact your JCB dealer.
Check (Level)
WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil.
Danger of scalding.
Notice: Do not exceed the maximum level of engine oil in the sump. If the maximum is exceeded, the
excess must be drained to the correct level. An excess of engine oil could cause the engine speed to
increase rapidly without control.
1. Make the product safe.

2. Wait for the oil to drain back into the engine sump before you take a reading. If not, a false low reading
may be recorded which can cause the engine to be overfilled.
3. Get access to the engine compartment (if applicable).
4. Remove and clean the dipstick.
5. Replace the dipstick.
6. Remove the dipstick.
7. Check the oil level. The oil should be between the two marks on the dipstick.
8. If necessary, add more oil:
8.1. Remove the filler cap.
8.2. Add the recommended oil slowly through the filler point
163 9831/1850-4 163

Maintenance
Engine

8.3. Replace the dipstick.
8.4. Remove the dipstick.
8.5. Check the oil level, if necessary add more oil.
8.6. Replace the dipstick
8.7. Replace the filler cap.
9. Close and secure the engine cover (if applicable).
Replace
CAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove
the plug.
CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.
Figure 113.
C G
H
A
B
I
A Drain plug (Sump) B O-Ring (Sump)

C Dust cap D Drain tube
E Oil filter canister F Seal
G Filter head H O-Ring (Filter housing drain plug)
I Filter housing drain plug

2. Get access to the engine compartment.
3. Place a suitable container below the sump drain plug.
4. Drain the oil in to a suitable container:
164 9831/1850-4 164

Maintenance
Engine
4.1. On machines with a sump plug, remove the sump drain plug and O-ring and let the oil drain.
4.2. On machines with a drain valve, remove the dust cap from the sump drain port. Attach the drain tube
and make sure the free end of the tube is in a suitable container. Screw in the drain tube assembly
and open the valve and let the oil drain.
5. When the oil has completely drained:
5.1. On machines with a sump plug, clean the sump drain plug. Install the sump drain plug with a new O-
ring. Tighten the sump drain plug to the correct torque value
5.2. On machines with a drain valve, unscrew the drain tube assembly and refit the dust cap.
6. Loosen and remove the filter housing drain plug and O-ring. Drain the oil.
7. Install the filter housing drain plug using a new O-ring. Tighten the filter housing drain plug to the correct
torque value.
8. Remove the filter canister.
8.1. Use a chain wrench if necessary.
9. Clean the seal face of the filter head.
10. Smear the new seal on the new filter canister with clean engine oil.
11. Install and tighten the new filter canister until the seal just contacts the filter head and then tighten the filter
canister at least 3/4 of a turn.
12. Add the correct specification and quantity of oil through one of the filler points to the maximum mark on
the dipstick.
12.1. Clean any spilt oil.
13. Fit the filler cap and make sure it is secure.
14. Operate the engine at idle speed until the oil pressure low warning light has extinguished and the new filter
primed before the engine speed is increased above idle speed.
15. Check for leaks.
16. Check the oil level when the oil has cooled.
16.1. Fill with clean engine oil, if necessary.
Drive Belt
Check (Condition)
Notice: A drive belt that is loose can cause damage to itself and/or other engine parts.
1. Make the product safe.

2. Open the engine compartment cover (if applicable).
3. Get access to the drive belt.
4. Check the drive belt tension, if necessary contact your JCB dealer for any service requirements.
5. Renew the belt if it has cracks or if it is frayed or has pieces of material missing. Contact your JCB dealer
for any service requirements.
165 9831/1850-4 165

Maintenance
Engine
6. Close and latch the engine compartment cover (if applicable).
Crankcase Ventilation
Clean
2. Open the engine compartment cover (if applicable).
3. Get access to the crankcase breather tube.
4. Inspect the breather tube for sludge, debris, or ice in the tube. Inspect the tube more frequently in icy
conditions.
5. If sludge, debris, or ice are found, remove the tube and clean it with detergent and warm water or a solvent.
Dry the tube with compressed air.
6. Visually inspect the tube for cracks or damage. If damage is found contact the appropriate authorized
engine repair representative.
7. Close and lock the engine compartment cover (if applicable).
Exhaust
Check (Condition)
Check that there are no exhaust system components missing.
Check that none of the components are excessively corroded.
Check that there are no leaks in the exhaust system.
Check that the exhaust system is secure.
Emissions Control System

General
166 9831/1850-4 166

Maintenance
Engine
SCR Refresh Status Lamp Definitions
Table 33.
Lamp Symbol Lamp Colour Lamp Definition Running Refresh Stationary Refresh
Available Available
Green Running SCR Yes Yes
(Selective Catalytic
Reduction) refresh
available
Amber Running SCR re- Yes Yes

fresh required
Red Stationary SCR re- No Yes

fresh required
Running Refresh
During normal machine operation you may be prompted to carry out a running refresh. The following screen
will be displayed.
Figure 114.
In order to enable a running refresh select the function using the tick key located adjacent to the display. During
a running refresh the machine can be operated as normal, this is an automatic and seamless process. Refer
to: Console Switches (Page 20).
You can opt not to run a refresh by scrolling down using the arrow keys, the following symbol will be displayed.
You can select the function using the tick key located adjacent to the display or by pressing the SCR refresh
inhibit switch.
167 9831/1850-4 167

Maintenance
Engine
Figure 115.
At any point during the running refresh you can stop the process by pressing the SCR refresh inhibit switch.
One LED (Light Emitting Diode) will illuminate. In order to continue with the refresh at any time you will need to
press the SCR refresh inhibit switch again, the LED will turn off and the running refresh will continue. If you opt
not to run a refresh at this time you will be prompted again every time the machine is keyed on. The machine
must be keyed off for at least 2 min minutes before the menu will become available again.
Stationary Refresh
Before starting the SCR stationary refresh procedure the following conditions must be met:
1. Clean under the bonnet to ensure there is no flammable material on hot surfaces (e.g. turbo, exhaust
manifold).
2. The diesel and AdBlue/DEF (Diesel Exhaust Fluid) tanks should be full.
3. Position the machine on flat level ground where the machine will not be a hazard or danger.
4. Ensure the loader arms and attachment is positioned safely on flat ground.
A stationary refresh can be run if a running refresh is in progress, the stationary refresh will override and take
priority over the running refresh.
Activation
1. Neutral must be selected.
2. Park brake must be applied.
3. The engine coolant must be greater than the figure specified.
Temperature: 75 °C ( 166.9 °F)
4. If necessary warm the engine by running at high revs and activating the auxiliary hydraulics (where fitted
ensure any powered attachments are disconnected).
5. When a stationary refresh is available the display will show an icon.
168 9831/1850-4 168

Maintenance
Engine
Figure 116.
A
A Stationary refresh available icon B Stationary refresh menu icon
6. Scroll through the menu to find the stationary refresh icon as shown.
Figure 117.
7. Press the tick icon on the display, the following screen will then be displayed
Figure 118.
8. Once all requirements are met all four boxes will show a green tick and the DEF refresh icon will change
from white to amber indicating that a stationary refresh is available.
9. Press the tick icon on the display or press the SCR stationary refresh switch, the following progress indicator
will then be displayed
169 9831/1850-4 169

Maintenance
Engine
Figure 119.
What to Expect and Do During a Stationary Refresh

1. During refresh the following screen will be displayed.
Figure 120.
2. The engine revs will increase from idle to 1500rpm. After 3 minutes the revs will increase to 2000rpm and
remain at this speed for approximately 30 mins. After this time the revs will drop to 1200rpm for 2 mins
to cool the exhaust system.
3. Do not operate the throttle, park brake or transmission control – this will cause the refresh process to stop
immediately.
4. Do not operate the hydraulic functions
5. The process can be interrupted at any time but will have to be repeated to clear the fault.
6. The operator should stay with the machine during this procedure.
7. After completion of a successful refresh the display will return to its default setting. The machine can now
return to normal operation.
8. If the refresh has not been successful repeat the process or contact your local JCB dealer.
170 9831/1850-4 170

Maintenance
Air Filter
Air Filter
General
Check (Condition)
Notice: Do not modify or install non JCB approved components to the engine induction system, otherwise
the engine emissions will be compromised.

2. Get access to induction system.
3. Check the system hoses for:
3.1. Condition.
3.2. Damage.
3.3. Security.
4. Replace the system hoses if necessary.
Outer Element
Replace
Notice: The outer element must be renewed immediately if the warning light on the instrument panel
illuminates.
Notice: The inner element of the engine air filter must be replaced with a new one. Do not attempt to clean
or wash the old element.
Notice: Do not run the engine with the air filter element removed.
A new inner element must be installed at least every other time the outer element is changed. As a reminder,
mark the inner element with a pen each time the outer element is changed.

2. Open the engine cover to access the air cleaner assembly.
3. Release the clips to remove the air inlet elbow and pre-cleaner body. Refer to Figure 123.
Figure 121.
B C
A
A Air cleaner assembly B Location pegs

C Pre-cleaner body
171 9831/1850-4 171

Maintenance
Air Filter
3.1. Pivot the pre-cleaner and elbow assembly upwards to disengage the pegs from the main aircleaner
body.
3.2. Lift the assembly out of the engine bay.
4. Remove the outer filter element. Refer to Figure 123.
4.1. Be careful, do not tap or knock the element.
5. If necessary, remove the inner filter element using the pull tab on the filter.
6. Clean the inside of the housing and the pre-cleaner body.
7. Make sure the air holes are clear. If required, you can remove the air inlet elbow from the pre-cleaner body
to assist cleaning.
8. Make sure that no foreign objects or dirt is allowed to enter the intake system or serious engine damage
may result.
9. Make sure that any debris are removed from the intake air plenum chamber.
10. Install the new filter elements then into the main air cleaner housing, push them firmly in so that they are
seated correctly.
11. Install the pre-filter and air inlet elbow (if required).
12. Install the air inlet assembly on to the engine:
12.1. Position the assembly at an angle and engage the top pegs in to the main air filter body.
12.2. Allow the intake assembly to pivot down so that the bottom clips can be correctly engaged.
12.3. Make sure that the seal around the air inlet elbow I is correctly engaged in the intake plenum.
12.4. Make sure that the scavenge pipe seal is engaged.
Figure 122.
E D
F
D Air inlet elbow E Seal

F Chamber
13. Close and secure the engine cover.

Figure 123.
K J H G C L
C Pre-cleaner body G Clips
H Outer filter element J Inner filter element
172 9831/1850-4 172

Maintenance
Air Filter
K Housing L Air holes
Pre-Cleaner
Clean
Check the intake and exhaust ports of the filter for blockages. Clean if necessary. Refer to: Service Points
(Page 148).
173 9831/1850-4 173

Maintenance
Fuel System
Fuel System
General
Check (Leaks)
2. Get access to the engine compartment (if applicable).
3. Check the engine compartment (if applicable), fuel lines and the area below for leaks.
Fuel Filter
Replace

2. Get access to the filter.
3. Drain and remove the separator bowl.
Refer to: Water Separator (Page 174).
4. Replace the fuel filter.
5. Install the separator bowl.
Figure 124.
A Filter B Bowl
Water Separator
Clean
Draining the Water Separator

174 9831/1850-4 174

Maintenance
Fuel System

2. Get access to the filter.
3. If there is water but no sediment, open the tap to drain the water. If there is any sediment in the bowl replace
the fuel filter element. Do not disconnect the electrical connector (if installed).
4. Tighten the drain tap when all the water is drained.
Figure 125.
A Tap B Bowl
175 9831/1850-4 175

Maintenance
Cooling System
Cooling System
General
Check (Leaks)
Before you start the machine, inspect the system for leaks:

2. Get access to the cooling pack.
3. Check the cooling system for leaks.
Coolant
Check (Condition)
Refer to: Coolant (Page 215).
Check (Level)
2. Let the engine cool.
3. Get access to the radiator filler cap and expansion bottle.
CAUTION! The cooling system is pressurised when the coolant is hot. When you remove the cap, hot
coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling
system.
4. Check the level of coolant in the radiator and in the expansion bottle. If necessary, top-up the system:
4.1. Carefully remove the filler cap.
4.2. If necessary top-up the coolant to the neck of the expansion tube.
4.3. If necessary top-up the coolant in the expansion bottle so that it is half full.
4.4. Install the filler cap, make sure that it is tight.
Cooling Pack
Clean
4. If necessary, use a soft bristle brush or compressed air to remove all debris from the cooling pack.
176 9831/1850-4 176

Maintenance
Cooling System
Check (Condition)
4. Check the condition of the hoses, radiator and fan for:
4.1. Condition.
4.2. Damage.
4.3. Security.
5. Replace the system hoses/radiator if necessary.
177 9831/1850-4 177

Maintenance
Brakes
Brakes
General
WARNING Do not use a machine with a faulty park brake.
WARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
Make sure that you obey all of the health and safety precautions before you test or adjust the park brake.
If you have any questions about the park brake test or adjustments, contact your local JCB dealer.
If you think the brakes are not operating correctly, get the machine checked by your local JCB dealer. Do not
use a machine with defective brakes.
Service Brake
Check (Operation)
WARNING Do not use a machine with a faulty park brake.
The service brakes on this machine are backed up by accumulators. In the event of accumulator failure, the
service brakes would be inoperative with the engine stopped.
The operation of the accumulators is checked regularly, using the following procedure:
1. Park the machine on solid, level ground, then lower the attachment to the ground.
2. Engage the park brake.
3. Stop the engine and exhaust the brake system by operating the service brake repeatedly.
4. Start the engine and run at high rpm for the time specified.
Duration: 1 min
5. Stop the engine, engage the service brake.
6. Count the number of operations of the brake pedal until the system is exhausted.
If less than 6 or the brake failure warning light illuminates immediately then one or more of the accumulators
may have failed and need immediate replacement.
178 9831/1850-4 178

Maintenance
Gearbox
Gearbox
Oil
Check (Level)
The transmission oil level must be checked with the engine running and only when the transmission oil is
between the specified temperatures. 80 –90 °C ( 175.9 –193.9 °F)
1. Make the machine safe with the lift arm lowered and the shovel rams fully retracted.
2. Put the transmission in neutral.
3. Engage the park brake and block all the wheels.
5. Inspect the transmission oil level sight glass to establish the oil level. Ignore any markings in the sight glass.
The minimum and maximum oil levels are indicated by the holes made in the structure.
Figure 126.
B
A
C
D
A Transmission oil level sight glass B Maximum hot level mark

C Minimum hot level mark D Cold level mark
6. If necessary, add the recommended oil through the filler point.

7. Clean, then Install the filler cap. Do not allow dirt to enter the filler port. Start the engine and make sure
the transmission oil is at the correct temperature.
8. Stop the engine.
9. Remove the articulation lock when all work in the articulation danger zone is completed and remove the
blocks.
179 9831/1850-4 179

Maintenance
Steering System
Steering System
General
Lubricate
Figure 127.
6,7 4,5
2 1
Centre Pivot: Total of 3 grease points (1 to 3).
Steer Rams: Total of 4 grease points (4 to 7).
180 9831/1850-4 180

Maintenance
Driveshafts
Driveshafts
General
Lubricate
Figure 128.
1 2 4 5 7
3 6
Total of 7 grease points.
181 9831/1850-4 181

Maintenance
Wheels
Wheels
General
Check (Condition)
WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine
hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the
machine being started while you are beneath it.
WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the
attachments or get caught in the linkages. Lower the attachments to the ground before doing these checks.
Also make sure that the park brake is engaged before doing these checks.
WARNING Whenever a wheel has been changed, check the nut torques every two hours. When the nuts
stay tight for 8 h, the interval for checking can revert to the period stated in the servicing schedule.
WARNING A machine can roll off jacks and crush you unless the wheels have been blocked. Always block
the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine
supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.
WARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure
that they cannot fall and cause injury. Use suitable lifting equipment if necessary.
Changing a Wheel
If for whatever reason a wheel bolt is renewed, all the bolts for that wheel must be replaced as a set, since
the remaining bolts may have been damaged.
Remove
2. Jack up the machine to gain access to whichever wheel you wish to change.
3. Remove the nuts then remove the wheel
Replace
1. Inspect the wheel for any damage, i.e. elongated holes.
2. Clean the hub, wheel mounting face and nut cones thoroughly if they are contaminated with paint, rust
or debris.
3. Ensure the wheel stud thread surface is maintained dry and is free from all lubricants.
4. Position the wheel on the hub.
5. Lightly tighten the nuts to ensure the wheel is correctly seated onto the hub.
6. Tighten the nuts in the sequence shown.
182 9831/1850-4 182

Maintenance
Wheels
Figure 129.
x4 x5
1 1 x6
1 3
3 4
3 4 6 5
5 2 4
2 2
1 1 x8
10 8 x10
8 6
3 6
3 4
4
5
5
7 9 7
2 2
7. Lower the machine to the ground.

8. Torque tighten the nuts in the sequence shown.
Checking the Wheel Nut Torques

WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed
as a set, since the remaining studs may have been damaged.
On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours
until they stay correct.
Every day, before starting work, check that the wheel nuts are tight.
183 9831/1850-4 183

Maintenance
Tyres
Tyres
General
Check (Condition)
WARNING Do not use the machine with damaged, incorrectly installed, incorrectly inflated or excessively
worn tyres. Recognise the speed limitation of the tyres installed and do not operate at more than their
recommended maximum speed.
WARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the
instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all
repair work.
WARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure
that they cannot fall and cause injury. Use suitable lifting equipment if necessary.
Checking the Tyre Condition

Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of
the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:
• Signs of distortion (bulges)

• Cuts or wear
• Embedded objects (nails, etc.)
Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre
pressures.
Inspect the tyre valve for leaks, when you check the tyre pressures.
Tyre Inflation
Always try to maintain your tyre pressure to the recommended settings. Using your machine with under-inflated
tyres means:
• Decreasing the machines stability

• Higher tyre temperatures
• Excessive strain of the tyre fabric
• More bulging of the sidewalls
• Shortens the tyres life.
Using the machine with over-inflated tyres is dangerous:
• It causes excessive tensile loads in the fabric: this makes a tyre more susceptible to cuts and punctures.
Do not cut or weld on the rim of an inflated tyre.
Always deflate the tyre before removing foreign obstacles from the tread.
Always check the tyre pressures with the machine in an unladen state.
After checking or amending the tyre pressure always replace and secure the valve cap.
Under special conditions (e.g. on sand) the air pressure in the tyre may be reduced after you have consulted
your JCB dealer or tyre manufacturer.
Procedure
These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure,
call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment
to do the job.
1. Prepare the wheel. Before you add air to the tyre, make sure it is correctly fitted on the machine or installed
in a tyre inflation cage. Refer to Figure 130.
184 9831/1850-4 184

Maintenance
Tyres
Figure 130.
2. Prepare the equipment.

2.1. Use only an air supply system which includes a pressure regulator. Set the regulator no higher than
1.38 bar (20 psi) above the recommended tyre pressure.
Refer to: Wheels and Tyres (Page 226).
2.2. Use an air hose fitted with a self-locking air chuck and remote shut-off valve.
3. Add the air.
3.1. 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.
3.2. Inflate the tyre to the recommended pressure. Do not over-inflate.
185 9831/1850-4 185

Maintenance
Hydraulic System
Hydraulic System
General
Discharge
WARNING Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine
if a hose or hose fixture is damaged.
1. Park the machine in the straight-ahead position on solid, level ground.

2. Lower the lift arm and put the attachment flat on the ground.
3. Engage the park brake.
4. Set the transmission to neutral.
5. Stop the engine.
6. Make sure the loader isolator switch is on (the switch will be illuminated when on).
7. Release the hydraulic pressure in a particular service, operate the related controls, including the auxiliary.
7.1. For example, to release the hydraulic pressure in the loader arms, unlock the loader controls, then
operate the loader controls lever repeatedly.
8. Turn the ignition key to the off position.
9. Make sure the pressure in the service hose line is released before the hydraulic hoses are connected or
disconnected.
Refer to: Connecting/Disconnecting Hydraulic Hoses (Page 110).
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal accidents. Examine the hoses regularly. Do not use the machine
if a hose or hose fixture is damaged.
WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid
under pressure and wear personal protective equipment. Hold a piece of cardboard close to suspected leaks
and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection covering
Replace a damaged hose before you use the machine again.
The replacement hoses must be of the same size, standard and pressure rating. If necessary, for more
information contact your JCB dealer.
Check (Leaks)
Notice: If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic
pump. Contact your JCB dealer immediately.
186 9831/1850-4 186

Maintenance
Hydraulic System

2. Open the access covers.
3. Check the hydraulic hoses for damage.
4. Close the access covers.
Services
Check (Operation)
Check the operation of all the hydraulic services. Check for:
• Speed of operation
• Strength of operation
• Juddering
• Abnormal noises.
Do not use the machine if one or more of these faults are found. You must make sure that the hydraulic service
is repaired immediately.
Oil
Check (Level)
CAUTION Do not run the machine with the hydraulic tank filler cap removed.

2. Look at the hydraulic fluid on the bullseye. If the hydraulic fluid is cloudy, water or air is the system. Water or
air in the system can damage the hydraulic pump. Contact your JCB dealer if the hydraulic fluid is cloudy.
3. Warm the hydraulic system of the machine to normal operating temperature.
4. The level of hydraulic fluid should be at the centre mark on the bullseye or in the bottom half close to the
centre mark.
5. If necessary, add the recommended hydraulic fluid:
5.1. Release the pressure from the hydraulic tank.
5.2. Get safe access to the hydraulic filler port.
5.3. Use a suitable container to add the hydraulic fluid through the filler port.
5.4. Check the level of hydraulic fluid.
187 9831/1850-4 187

Maintenance
Hydraulic System
Cylinders / Rams
Check (Condition)
Extend each ram fully, one at a time and visually examine for score marks, dents, leaks or similar defects.
Make the machine safe before inspecting each ram.
If a ram piston appears defective, contact your service engineer or JCB dealer.
Hose Burst Check Valves

Check (Operation)
WARNING Keep people clear of the machine while you do these checks.
The hose burst check valves 'lock' to prevent the uncontrolled movement of the ram pistons if the hydraulic
pressure fails or a hose bursts. The valves are installed directly on the rams.
Keep people clear of the machine while you do these checks.
The machine must have an attachment installed for the test to operate correctly.

2. Raise and extend the lift arm to its maximum position, then move the attachment to a horizontal position.
3. Stop the engine.
4. Turn the ignition key to the on position.
5. Use the control lever to try to lower the lift arm and tip the attachment. If there is any movement, get the
hydraulic system checked by your JCB dealer.
6. Use the extend/retract function to try to retract the lift arm. If there is any movement, get the hydraulic
system checked by your JCB dealer.
188 9831/1850-4 188

Maintenance
Electrical System
Electrical System
General
Check (Operation)
Make sure all of the electrical equipment operates correctly, for example:
• Switches
• Warning lights
• Beacon
• Alarms
• Horn
• Wipers
• Hourmeter/display
• Battery
• Lights
All defective equipment must be repaired before the machine is used.
Check (Condition)
DANGER Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep
the battery away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from
the battery terminals. Such items could short the terminals and burn you.
Set all switches to off before disconnecting and connecting the battery. When disconnecting the battery,
take off the earth (-) lead first.
Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have installed the battery in the machine, wait 5 min
before connecting it up.
When reconnecting, attach the positive (+) lead first.
DANGER Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke
close to the battery. Make sure there is good ventilation in closed areas where batteries are being used
or charged. Do not check the battery charge by shorting the terminals with metal. Use a hydrometer or
voltmeter.
WARNING Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep
the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.
CAUTION Understand the electrical circuit before connecting or disconnecting an electrical component. A
wrong connection can cause injury and/or damage.
Examine the electrical circuits regularly for:
• Damaged connectors
• Loose connections
• Chafing on the wiring harnesses
• Corrosion
• Missing insulation
• Incorrect routing of the wiring harnesses.
Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit
is repaired immediately.
Battery
Clean
189 9831/1850-4 189

Maintenance
Electrical System

2. Get access to the battery.
3. If the terminal posts are corroded and covered with white powder wash them with hot water. If there is
considerable corrosion, clean the terminal posts with a wire brush or abrasive paper. Refer to Figure 131.
Figure 131.
4. Apply a thin layer of petroleum jelly to the terminal posts.
Connect
WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+)
battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can
get burned.
CAUTION The machine is negatively earthed. Always connect the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.
1. Get access to the batteries.

Refer to: Disconnect (Page 190).
2. Connect the battery leads. Connect the earth (-) terminal last.
3. If the machine has a battery isolator, move the switch to the on position.
Disconnect
WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+)
battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can
get burned.
CAUTION The machine is negatively earthed. Always connect the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.
Notice: Do not disconnect the battery while the engine is running, otherwise the electrical circuits may
be damaged.
190 9831/1850-4 190

Maintenance
Electrical System

2. Get access to the batteries.
3. If the machine has a battery isolator, move the switch to the off position then remove the key.
4. Disconnect the battery leads. Disconnect the earth (-) terminal first.
Battery Isolator
Check (Operation)
Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the
machine electrics.
1. Isolate the machine electrics.

2. Make sure that the machine electrics are isolated.
A defective isolator must be repaired before the machine is used. For more information, contact your JCB
dealer.
Fuses
Replace
Notice: Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
The electrical circuits are protected by fuses. If a fuse breaks, find the cause and correct the fault before a new
fuse is installed. For more information on the individual fuses Refer to: Fuses (Page 217).
Primary Fuses
The primary fuses are in two adjacent fuse boxes which are installed either on the left or right side of the engine
compartment rear bulkhead.
Depending on the machine model, up to two additional primary fuses are also mounted on the bulkhead,
(depending on the specification of the machine).
If a fuse breaks, find the cause and correct the fault before a new fuse is installed.
To get access to the fuses:

2. Open the engine cover.
Refer to: Engine Compartment Cover (Page 150).
191 9831/1850-4 191

Maintenance
Electrical System
Figure 132.
B
C D
A Primary fusebox (top) B Primary fusebox (bottom)

C Additional primary fuse (secondary steer) D Additional primary fuse (grid heater)
192 9831/1850-4 192

Maintenance
Electrical System
Secondary Fuses
The fuses are situated in a fuse box (shown with the cover removed) behind the operators seat.
To get access to the fuses:

2. Open the operator door and enter into the cab.
3. Remove the cover (not shown) to access the secondary fuses.
Figure 133.
A Secondary fuses
Relays
Replace
The relays are situated in a fuse box (shown with the cover removed) behind the operators seat.
To get the access to the relays:

2. Open the operator door to enter into the cab.
3. Remove the cover (not shown) to access the secondary fuses.
193 9831/1850-4 193

Maintenance
Electrical System
Figure 134.
A Relays
Figure 135.
A B
A Secondary steer relay B Grid heater relay
Window Washer
Check (Level)
2. Get access to the front window washer bottle.
3. Remove the filler cap.
194 9831/1850-4 194

Maintenance
Electrical System
4. Fill the washer bottle with clean water. The liquid should contain a de-icing fluid to prevent it freezing.
5. Replace the filler cap.
Do not use engine coolant antifreeze.
Do not use the window washer when there is no liquid in the washer bottle as it will cause damage to the motor.
195 9831/1850-4 195

Maintenance
Miscellaneous
Miscellaneous
Fire Extinguisher
Check (Condition)
In addition to the operator check the extinguisher must be serviced every 12 months by a suitably qualified
person.
1. Examine the fire extinguisher for damage and leaks.

2. Make sure the fire extinguisher is correctly attached.
3. Make sure that the gauge indicates that the extinguisher is charged i.e. the needle is in the green segment
3.1. If the needle is in or very near the red segment at either end of the gauge, the extinguisher must be
serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 136.
A Gauge B Safety Pin
196 9831/1850-4 196

Technical Data
Static Dimensions
Technical Data
Static Dimensions
Dimensions
For: 411HT [T4F], SJ Engine ................................................................................................. Page 197
For: 413S [T4F], DJ Engine ................................................................................................... Page 198
(For: 411HT [T4F], SJ Engine)

Figure 137.
L
K
F
J B C D
H A
Table 34.
Description Dimensions
A Overall length 6,263 mm
B Axle to pivot pin 1,223 mm
C Wheel base 2,752 mm
D Axle to counterweight face 1,398 mm
E Minimum ground clearance 345 mm
F Height over exhaust 1,719 mm
G Width over cab roof 1,540 mm
H Maximum width over tyres 2,250 mm
J Wheel track 1,801 mm
K Height over cab roof and lowered beacon 2,487 mm
L Height over raised beacon 2,849 mm
197 9831/1850-4 197

Technical Data
Static Dimensions
(For: 413S [T4F], DJ Engine)

Figure 138.
L
K
F
J B C D
H A
Table 35.
198 9831/1850-4 198

Technical Data
Static Dimensions

Figure 139.
L
K
F
J B C D
H A
Table 36.
199 9831/1850-4 199

Technical Data
Lift Arm Dimensions and Performance
For: 411HT [T4F] .................................................................................................................... Page 200
For: 413S [T4F] ...................................................................................................................... Page 200
For: 417HT [T4F] .................................................................................................................... Page 200
(For: 411HT [T4F])
Table 37. General purpose shovel (Direct mount)

Shovel size Shovel weight Full turn tip load Payload
(1)
1.2 m³ 528 kg 5,585 kg 2,793 kg

1.4 m³ 603 kg 5,451 kg 2,726 kg
(1) The payload is 50% of the full turn tip load.
Table 38. General purpose shovel (Quickhitch mount)

(1)
1.2 m³ 505 kg 5,337 kg 2,669 kg

1.4 m³ 580 kg 5,182 kg 2,591 kg
Table 39. Pallet forks (Quickhitch mount)

Weight Full turn tip load Payload
(1)
435 kg 4,200 kg 3,360 kg

(1) The payload is 80% of the full turn tip load at 500 mm load centre.
(For: 413S [T4F])

(1)
1 m³ 386 kg 4,793 kg 2,397 kg

1.2 m³ 528 kg 5,616 kg 2,808 kg

(1)
435 kg 4,158 kg 3,326 kg

(For: 417HT [T4F])
Table 42. General purpose shovel (Direct mount)

(1)
1.4 m³ 680 kg 6,129 kg 3,065 kg

1.6 m³ 720 kg 6,042 kg 3,021 kg
200 9831/1850-4 200

Technical Data

(1)
1.4 m³ 665 kg 5,847 kg 2,924 kg

1.6 m³ 705 kg 5,767 kg 2,884 kg

(1)
435 kg 4,653 kg 3,722 kg

Driving Performance
For: 411HT [T4F] .................................................................................................................... Page 201
For: 413S [T4F] ...................................................................................................................... Page 202
For: 417HT [T4F] .................................................................................................................... Page 202
(For: 411HT [T4F])

Figure 140.
O
40
R1 R2
R3
Table 45.
Tyre Shovel R1 (Outer shovel R2 (Outer tyre ra- R3 (Inner tyre ra-
radius) dius) dius)
15.5 R25 XHA 1.2 m³ 5,351 mm 4,915 mm 2,688 mm
201 9831/1850-4 201

Technical Data
(For: 413S [T4F])

Figure 141.
O
40
R1 R2
R3
Table 46.
radius) dius) dius)
460/70 R24XMCL 1 m³ 5,445 mm 4,986 mm 2,617 mm
(For: 417HT [T4F])

Figure 142.
O
40
R1 R2
R3
202 9831/1850-4 202

Technical Data
Table 47.
radius) dius) dius)
17.5R25 XHA L3 1.4 m³ 5,463 mm 5,011 mm 2,704 mm
Towing Weights
(For: 413S [T4F], 417HT [T4F])

Table 48.
Hitch Type Recovery Hitch
(1)
Hydraulic Hitch
Brake System Maximum Trailer Mass
(2)
Unbraked 750 kg 750 kg

Inertia braked 3,500 kg 3,500 kg
Independently braked 3,500 kg 6,000 kg
Proportional assisted braking 3,500 kg 8,000 kg
(1) The recovery hitch is only suitable for occasional off-highway use.
(2) Local legislation may limit the maximum trailer mass.
Table 49.
Brand Tyre Size Maximum Allowable Vertical Hitch Load
(2)
Recovery Hitch
(1)
Hydraulic Hitch
Michelin XHA 17.5R25 500 kg 1,600 kg
XTLA 17.5R25 500 kg 1,600 kg
XSNOPLUS 17.5R25 500 kg 1,600 kg
XMCL 460/70R24 500 kg 1,600 kg
XMCL 500/70R24 500 kg 1,600 kg
XMCL 540/70R24 500 kg 1,600 kg
XM27 620/70R26 500 kg Not suitable
CERE XBIB 620/70R26 500 kg 1,600 kg
MEGA XBIB 620/75R26 500 kg 1,600 kg
MEGA XBIB 750/50R26 500 kg 1,600 kg
Nokian L GRIP 17.5R25 500 kg 1,600 kg
L GRIP 2 15.5R25 500 kg 1,600 kg
GRS 17.5R25 500 kg 1,600 kg
Trelleborg 600/55 R26.5 500 kg 1,600 kg
(1) The recovery hitch is only suitable for occasional off-highway use.
(2) The tyres will deflect and distort under load and can have a effect on machine stability. Make sure the tyres
are inflated to correct pressure. Refer to: Technical Data > Wheels and Tyres > Tyre Sizes and Pressures.
203 9831/1850-4 203

Technical Data
Noise Emissions
Noise Emissions
General
To assist in compliance with European Directives 2000/14/EC and 2005/88/EC, the noise data values for this
type of machine have been provided on the following page(s) and may be used for the assessment of risks
to exposure from noise.
The noise data values shown only apply to CE marked machines.
For information relating to this machine when used with other JCB approved attachments, please refer to the
literature accompanying the attachments.
Table 50. Definition of terms

Term Definition Notes
LpA A-weighted sound pressure level mea- Determined in accordance with the test method
sured at the operator's station. defined in ISO 6396 and the dynamic test condi-
tions defined on 2000/14/EC.
LwA Equivalent A-weighted sound power level Guaranteed equivalent sound power (external
emitted by the machine. noise) determined in accordance with the dynamic
test conditions defined in 2000/14/EC.
Noise Data

Table 51.
Engine rating
(1)
LpA LwA
81 71 103
(1) Net installed power (kw).

Table 52.
Engine rating
(1)
LpA LwA
108 71 104

Table 53.
Engine rating
(1)
LpA LwA
93 71 104
204 9831/1850-4 204

Technical Data
Vibration Emissions
Vibration Emissions
General
To assist in compliance with the European Directive 2002/44/EC, the duty specific vibration emission values
for this machine type have been provided on the following page(s) and may be used for the assessment of
risks to exposure from vibration.
Unless otherwise indicated for a specific operating condition, the vibration values are calculated with the
machine equipped with the standard attachments (for example bucket, shovel, fork, etc.) for the respective
operating condition.
The vibration values are calculated from measurements in three perpendicular axes (X, Y and Z). The highest
weighted (RMS (Root Mean Square)) value is used to specify the vibration emission.
The axis upon which the highest weighted (RMS) value occurs is shown on the vibration chart for each of the
machine operating duties, see dominant axis (X, Y or Z).
Figure 143.
Exposure to Vibration
Exposure to vibration can be minimised through:
• Selection of the correct size and capacity of machine, equipment and attachments for a particular
application
• Use of a machine equipped with an appropriate seat, keeping the seat maintained and adjusted
• Checks to make sure that the machine is correctly maintained, reporting and correcting any faults
• Steering, braking, accelerating, shifting gears, moving the attachments and load smoothly
• Adjusting the machine speed and travel path to minimise the vibration level
• Keeping the terrain on worksites where the machine works and travels in good condition, removing any
large rocks or obstacles and filling in any ditches and holes
• Choosing routes that avoid rough surfaces and, if this is not possible, drive more slowly to avoid bumping
and jolting
• Travel over longer distances at an adjusted (medium) speed
• Avoiding bad postures, i.e. slumping in your seat, constantly leaning forward or sideways or driving with
your back twisted.
205 9831/1850-4 205

Technical Data
Vibration Emissions
Operator Seat Specification

This machine has an operator seat which meets the criteria of EN ISO 7096:2000 (representing vertical vibration
input under severe but typical operating conditions). The input spectral class which relates to this machine and
seat combination is EM3 - Wheel Loader (Operating capacity > 4,500 kg).
Vibration Data
The whole-body vibration emission under representative operating conditions (according to the intended use)
are shown.
Figure 144.
Y X Y Y X
m/s² A(8)
0.70
0.58
0.49 0.49
0.06
D1 D2 D3 D4 D5
X-Z Dominant axis D1 Machine operating duty: Low idle
D2 Machine operating duty: Roading (tarmac) D3 Machine operating duty: Roading (rough
terrain)
D4 Machine operating duty: Loader work (soil) D5 Machine operating duty: Loader work (stone)
The whole-body vibration emission calculated in accordance with ISO (International Organization for
Standardization) 2631-1:1997 for this machine type is 0.58 m/s² normalised to an 8 h reference period [A(8)]
and based upon a test cycle comprising of 'loader work (soil)'.
The hand-arm vibration calculated in accordance with the dynamic test conditions defined in ISO 5349-2: 2001
does not exceed 2.5 m/s².
The errors bars are due to variations in vibration emissions due to measurement uncertainty ( 50 % in
accordance with EN 12096:1997).
206 9831/1850-4 206

Technical Data

General

JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB
machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or
offer the same machine component protection.
Table 54. Specifications

Item Capacity Fluid/Lubricant JCB Part Num- Container Size(1) Specification
ber
Fuel Tank Main 116 L Diesel
Auxiliary 111 L
DEF (Diesel Ex- 20 L DEF 4009/0100
haust Fluid) tank
Engine (Oil) 14 L JCB Engine Oil 4001/3405 USA 20 L API CJ-4
Ultra Perfor-
mance 5W40
-30 ( -22 )
and below 50
( 122 )
JCB Engine Oil 4001/2705 (Ex- 20 L
Ultra Perfor- cept USA)
mance 5W40
-30 ( -22 )and
below 46 ( 115 )
JCB Engine Oil 4001/3005 20 L
Ultra Perfor-
mance 10W30
-10 ( 14 )and
below 46 ( 115 )
Engine (Coolant) 26 L JCB Antifreeze 4006/1120 20 L
HP/Coolant
(ASTM D6210)
Gearbox
(2)
27 L JCB HP Univer- 4000/2305 20 L
sal ATF
Axles
(2)
25 L JCB Gear Oil HP 4000/2205 20 L
Plus
Hydraulic sys- 155 L JCB Hydraulic 4002/1605 20 L
tem
(3, 4)
Fluid EP46
Grease points JCB Special HP 4003/2017 24x400g
Grease
(5)
Auto greasing JCB Special 4003/1501 24x400g

system (If in- MPL EP Grease
stalled)
207 9831/1850-4 207

Technical Data

ber
Electrical con- As a corrosion and moisture inhibitor, all exposed
nections connections should be coated liberally with petrole-
um jelly.
Tow Hitch Extreme Per- 4003/1327 24x400g
formance Moly
Grease
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB Dealer
(2) The figure quoted is total system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling
the system.
(3) The total hydraulic system capacity depends on the equipment being used. Fill the system with all of the
rams closed and watch the level indicator.
(4) Biodegradable Hydraulic Fluid is a factory option Only. Replenish with JCB Biodegradable Multigrade
Hydraulic fluid. For further information, contact Wheeled Loader Technical Service.
(5) If JCB Special MPL Grease is used for normal greasing, all 100 hour greasing operations must be carried
out at 10 hour intervals.


ber
Auxiliary 111 L
DEF tank 20 L DEF 4009/0100
Ultra Perfor-
mance 5W40
-30 ( -22 )
and below 50
( 122 )
mance 5W40
-30 ( -22 )and
below 46 ( 115 )
Ultra Perfor-
mance 10W30
-10 ( 14 )and
below 46 ( 115 )
HP/Coolant
(ASTM D6210)
Gearbox
(2)
27 L JCB HP Univer- 4000/2305 20 L
sal ATF
Axles
(2)
Plus
tem
(3, 4)
Fluid EP46
208 9831/1850-4 208

Technical Data

ber
Grease
(5)

system (If Fitted) MPL EP Grease
um jelly.
formance Moly
Grease
JCB Dealer
the system.


ber
Auxiliary 111 L
DEF tank 20 L DEF 4009/0100
Ultra Perfor-
mance 5W40
-30 ( -22 )
and below 50
( 122 )
mance 5W40
-30 ( -22 )and
below 46 ( 115 )
Ultra Perfor-
mance 10W30
-10 ( 14 )and
below 46 ( 115 )
HP/Coolant
(ASTM D6210)
Gearbox
(2)
27 L JCB HP Univer- 4000/2305 20 L
sal ATF
209 9831/1850-4 209

Technical Data

ber
Axles
(2)
Plus
tem
(3, 4)
Fluid EP46
Grease
(5)

system (If Fitted) MPL EP Grease
um jelly.
formance Moly
Grease
JCB Dealer
the system.
Fuel
Acceptable and Unacceptable Fuels

WARNING Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the
petrol will form flammable vapours.
Notice: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the
failure is attributed to the quality and grade of the fuel used.
Notice: Sulphur can be detrimental to the emissions performance of your machine and it is in your interest
to ensure Ultra Low Sulphur Diesel (ULSD) is used. Failure to adhere to local emissions regulations will
result in no support and no warranty liability being accepted on any machine.
Fuel Groups
The major world fuels standards are divided into four categories. Those that are fully accepted as suitable fuels,
those that are acceptable from a "warranty" point of view, but may have undesirable affects on the expected
life of the engine performance, those that will reduce the expected life, and lastly those that are viewed as
unacceptable for use (fuels shown on the same line as each other are considered equivalents).
The lists below are not exhaustive of all diesel fuel standards encountered in the marketplace. If comment
is required on the suitability of fuel standards not on the list, requests with, if possible, specification details
showing at least the key characteristics described above should be forwarded to JCB Service for assessment
and comment.
210 9831/1850-4 210

Technical Data
Table 57. Group 1

Fuel Advice Service Requirements
EN590 Diesel fuel types - Auto/C0/ Preferred and may be used with no For fuel with unspecified parame-
C1/C2/C3/C4 Sulphur < 10ppm. restrictions or conditions. ters, EN590 values apply. Fuel
BS2869 Class A2 Sulphur < grades within each standard must
10ppm be appropriate to the ambient tem-
perature. The appropriate level of
ASTM D975-076 2-D, US DF1, US
fuel cleanliness at the FIE inlet af-
DF2, US DFA Sulphur < 15ppm
ter filtration has to be ensured by
JIS K2204 Grades 1, 2, 3 and Spe- the customer.
cial Grade 3 Sulphur < 10ppm
Table 58. Group 2

Fuel Advice Service Requirements
Group1 fuels with HFFR WSD in Not preferred and may be used but
the range 460 to 520 may lead to reduced FIE life and /
ASTM D975-91 Class 1-1DA or loss of performance.
(1) See your JCB dealer for advice on service requirements.
Table 59. Group 3

Fuel Advice
AVTUR FS11 (NATO F34, JP8, MIL T83133, DEF Not preferred and may be used only with appropri-
STAN 91-87, DERD 2463) ate additives and will lead to reduced FIE life and / or
AVCAT FS11 (NATO F44, JP5, MIL T5624, DERD loss of performance.
2452, AVTOR))
JET A1 (NATO F35, DEF STAN 91-91, DERD 2494)
AVCAT (NATO F43, JP5 without additives)
JET A (ASTM D1655)
ASTM D3699 Kerosene
JP7 (MIL T38219 XF63)
NATO F63
Table 60. Group 4

Fuel Advice
Unmodified Vegetable Oils and Biodiesels over 20 Unacceptable
% concentration
Additives
The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low
sulphur fuels up to those of diesel fuels.
These products are given as examples only. The information is derived from the manufacturers data. The
products are not recommended or endorsed by JCB. Contact your JCB dealer for further advice.
• Elf 2S 1750. Dosage 1000-1500 ppm ( 0.1 % to 0.15 %), specifically for Indian Superior Kerosene (SKO)
but may be applicable to other fuels.
• Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.
• Paradyne 7505 (from Infineum). Dosage 500 ppm ( 0.05 %).
Warranty
JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels.
Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required.
211 9831/1850-4 211

Technical Data
Failure to follow the additional recommended service requirements may lead to a warranty claim being declined.
Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the engine
workmanship and therefore will not be supported by JCB Warranty.
Usage and Effects of Fuels

The information that follows indicates types of fuel that are acceptable or unacceptable.
Acceptable Fuels
Ultra Low Sulphur Diesel (EN590)
Available throughout the UK, Europe and North America since March 1999. This fuel has a maximum sulphur
content of 0.001 % ( 0.0015 % in North America) by weight and a further reduction in the natural lubricity and
aromatic content than experienced with low sulphur diesel. Major oil producers will add lubrication improvers
and also maintain the total aromatic content to an acceptable level.
Unacceptable Fuels
B20 Biodiesel
Biodiesel refers to pure fuel before it is blended with diesel fuel. When biodiesel is blended with diesel fuel it
is referred to as B5, B20 etc., where the number indicates the percentage of biodiesel in the fuel, for example
B5 contains 5 % biodiesel.
Biodiesel has different characteristics than mineral based fuels, this could lead to seals swelling, fuel system
corrosion and seal damage.
Using B20 biodiesel can result in poisoning of the SCR (Selective Catalytic Reduction) system.
The natural properties of biodiesel make it a good medium for micro bacterial growth, these microbes can
cause fuel system corrosion and early fuel filter blocking.
B100 - Chemically Modified Vegetable Oils (FAME/ VOME)

These fuels have been derived from a wide range of vegetable oils and animal fats, resulting in better stability,
viscosity and cetane number than those produced from unmodified vegetable oils, but it is recognised that
there are potential problems associated with the finished fuel characteristics. These oils are less stable than
mineral oil derived fuels when stored and they will readily degrade producing fatty acids, methanol and water,
none of which are desirable in the FIE. These effects are known to be accelerated when the fuel is stored in
the presence of air and water together.
An extract 'common statement' from the FIE manufactures specifies that "The fuel injection equipment
manufacturers can accept no liability whatsoever for failure attributable to operating their products with fuels
for which the products were not designed, and no warranties or representations are made as to the possible
effects of running these products with such fuels".
Unmodified Vegetable Oils

Burned in diesel engines neat or used as an extender to mineral derived fuel. When these are subjected to
heat in the fuel injection system they form sticky deposits that can be found inside the fuel pump and a hard
lacquer in the injectors where exposure to even higher temperatures takes place.
Sulphur Content
Notice: A combination of water and Sulphur will have a corrosive chemical effect on fuel injection
equipment. Use of high Sulphur fuels will poison the Selective Catalytic Reduction (SCR) catalyst (if fitted)
and must not be used. Ultra Low Sulphur Diesel (USLD) should always be used. Ultra Low Sulphur Diesel
(ULSD) has a Sulphur content of less than 10 ppm (US 15ppm).
212 9831/1850-4 212

Technical Data
Effects of Fuel Contaminates

The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment:
Dirt
A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor
rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to
greater leakage, uneven running and poor fuel delivery.
Water
Water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel
tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump
as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is
prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly.
Wax
Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing
a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine
operation at temperatures below 0 °C ( 32.0 °F). These fuels have a lower viscosity and limit wax formation.
Chemical Contamination
It should be noted that exposure of fuel to surfaces containing Copper (Cu), Zinc (Zn) or Lead (Pb) can adversely
affect fuel quality and should be minimised.
Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid (DEF)

the failure is attributed to the quality and grade of the diesel exhaust fluid (DEF) used.
the failure is attributed to contamination of the diesel exhaust fluid (DEF).
This engine has exhaust gas treatment using selective catalytic reduction technology. In SCR (Selective
Catalytic Reduction) technology, a liquid called diesel exhaust fluid is injected into the exhaust gasses. DEF
(Diesel Exhaust Fluid) is used within SCR systems on diesel engines to reduce harmful exhaust gas emissions
known as NOx. When the DEF is injected into the exhaust stream it turns into ammonia and water, this ammonia
enters the catalyst and reacts with the NOx molecules to form nitrogen and water. Naturally occurring and
harmless, they are then released into the atmosphere.
The DEF consumption depends on the duty cycle of the engine.
DEF is a highly purified, colourless liquid containing demineralized water 67.5 % and Urea 32.5 %. DEF is
specified under ISO 22241 and is marketed under various names such as AdBlue®, ARLA 32 or AUS 32.
Make sure that genuine DEF is used. Do not dilute DEF or mix it with other substances, it may damage the
catalyst.
The DEF tanks and pipes are heated if there is any danger of freezing, the congealing point of DEF at 32.5
% is -11 °C ( 12.2 °F). The DEF storage tank on the machine will be heated from the engine cooling system
automatically.
If a problem is detected within the DEF system for any problem including contamination, engine power will
be reduced.
213 9831/1850-4 213

Technical Data
Storage
Always use polyethylene, polypropylene, stainless steel or plastic containers for storing DEF, as DEF can be
corrosive to most metals (eg steel, copper , and aluminium). This applies to any funnels, jugs, pipes, pumps
and other handling equipment
Avoid decanting wherever possible to prevent contamination from dirt or trace amounts of metals that can occur
when metal containers are used. Even the use of apparently clean items such as jugs or funnels may introduce
damaging contaminants if they have ever been used for other purposes.
Always ensure any caps on DEF storage containers are screwed tight to prevent evaporation and crystallisation.
DEF can be stored for up to 12 months in a sealed container, and must be kept between -6 °C ( 21 °F) and
25 °C ( 77 °F) in a shaded area out of direct sunlight and ultraviolet radiation.
Spillages
A small DEF spill can be diluted with water. It is best to mop up the spillage and avoid flushing it down a drain
or waterway
In case of a large spill, try to prevent the spillage from entering drains or waterways. Contain the spill with sand,
earth or your spill kit and dispose of it properly
The surface on which you spill DEF may become slippery. Make sure that you clean up the spill as quickly as
possible to prevent slips and falls.
If a spill occurs on the machine, wash away with water as white crystals will form and these will eventually
become corrosive to paintwork and, in turn, metal work
DEF should never be spilled onto electrical connectors as it will destroy terminals quickly. It can also travel
easily by capillary action between the insulation and copper wires in harnesses.
Preventing Contamination of the DEF tank

In order to prevent damage to the SCR system, DEF used must be compliant to the ISO 22241-1 standard.
ISO 22241-1 DEF is available from all JCB dealers
Every machine equipped with a JCB SCR system is fitted with a quality sensor in the DEF tank to help prevent
problems caused by cross contamination with other fluids
DEF needs to be kept free from dirt and other particle contaminants at all times to prevent damage to the SCR
system. There is a mesh strainer fitted in the JCB DEF filler.
DEF needs to be kept free from liquid contaminants such as diesel, oil, antifreeze, screenwash and other fluids
at all times. Even one drop of diesel or oil can pollute 20 L of DEF.
If diesel is poured into the DEF tank this can damage the after treatment system, do not start the engine, please
contact your local JCB dealer immediately so they can correctly flush the system to avoid an expensive repair.
A range of special tools and fluid analysis services are available at your local JCB dealer to check DEF quality
via simple hydrocarbon test paper strips, or a more comprehensive laboratory service. Digital and optical
concentration measuring devices are also available.
If any cross contamination is detected JCB will not be liable for any further diagnosis or repairs to the SCR
system.
Preventing Cross Contamination of Diesel Fuel and DEF

The opening for your DEF tank is narrower than the opening for a diesel tank, so you should not be able to
put diesel in the wrong tank (as the nozzle does not fit)
214 9831/1850-4 214

Technical Data
The DEF cap on every JCB machine is blue and clearly marked with AdBlue ®, DEF and the ISO (International
Organization for Standardization) symbol in white lettering . There are warning decals next to the DEF filling
point
The diesel cap is also clearly marked with lettering.
Every JCB DEF cap is lockable with a special key with a blue key fob, which can be given to a site supervisor
or other person of responsibility.
There is a special magnet fitted in the DEF filler neck which will allow some DEF electric dispensing pumps to
start if it has the matching ISO feature, as all forecourt dispensing systems have, thus preventing DEF being
dispensed if nozzle is not in the DEF tank.
If contamination occurs do not start the engine. Please contact your local JCB dealer immediately so they can
correctly flush the system to avoid an expensive repair.
Coolant
CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or
diluted antifreeze.
Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.
Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.
You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate
hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on
water hardness, contact your local water authority.
The correct concentration of antifreeze protects the engine against frost damage in winter and provides year
round protection against corrosion.
The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below.
Table 61.
Concentration Level of protection
50 % (Standard) Protects against damage down to -40 °C ( -40 °F)
60 % (Extreme Conditions Only) Protects against damage down to -56 °C ( -69 °F)
Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with International Specification ASTM D6210.
• Always read and understand the manufacturer's instructions.
• Make sure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if
corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).
215 9831/1850-4 215

Technical Data
Torque Values
Torque Values
General
For: 411HT [T4F], 413S [T4F] ................................................................................................ Page 216
For: 417HT [T4F] .................................................................................................................... Page 216
(For: 411HT [T4F], 413S [T4F])

Table 62. Torque Values
Item Torque
N·m
ROPS (Roll-Over Protective Structure)/FOPS (Falling 330
Object Protective Structure) (cab mounts) Bolts
Front and rear wheel nut 500
(For: 417HT [T4F])

Table 63. Torque Values
Item Torque
N·m
ROPS/FOPS (cab mounts) Bolts 330
Front and rear wheel nut 600
216 9831/1850-4 216

Technical Data
Electrical System
Electrical System
General
Table 64.
Item Specification
System voltage 24 V
Bulbs
Table 65.
Bulb Rating (W)
Headlights - Main 75
Headlights - Dip 70
Indicators 21
Halogen work lights 70
Halogen number plate 5
Tail lights 5
Front sidelights 5
Interior lights 10
Stop lights 21
Beacon 70
Rear fog lights 21
LED (Light Emitting Diode) work lights 28 and 33 options
Fuses
Primary Fuses
The primary fuse box covers have identification arrow symbol on each cover.
If you remove the fuse box covers make sure you install them at the correct location as indicated on the cover.
• Arrow symbol pointing top indicates the top fuse cover

• Arrow symbol pointing bottom indicates the bottom fuse cover
Figure 145.
6 7
5 8
2 3
1 4
Table 66. Primary Fuses

Fuse Circuit(s) Protected Amperage
1 I/O Module 1 40
2 Fuses A7, A8, B6, B7, B8 30
3 Main Start Relay, HVAC Relay, Ig- 40
nition Switch for fuses A1, A2, A3,
A4, A5, A6, A9, A10
217 9831/1850-4 217

Technical Data
Electrical System
Fuse Circuit(s) Protected Amperage

4 Ign Relay 1 for fuses C1, C2, C3, 30
C4, Ign Relay 2 for fuses C5, C6,
C7, C8
5 I/O Module 2 30
6 Fuses B1, B2, B3, B4, B5 30
7 Engine ECU (Electronic Control 30
Unit)
8 Dosing Control Unit 30
Additional Primary Fuses

Figure 146.
A B
125A 125A
Table 67.
Fuse Circuit(s) Protected Rating
A Secondary steer 125 A
B Grid heater 125 A
218 9831/1850-4 218

Technical Data
Electrical System
Secondary Fuses
Figure 147.
Table 68.
A1 Instrument panel 3A
Keypads
Rear camera
A2 ZF ECU 7.5 A
A3 Seat switch 7.5 A
A4 RHS fog 15 A
Reverse lamp
Trailer electrics enable
A5 Ignition relays 3A
Alternator
A6 Immobiliser 3A
A7 Alternator 3A
A8 Rear heated screen 20 A
A9 Engine ECU 3A
A10 Management ECU 3A
Engine pod box ( 12 V)
B1 RH column switch 7.5 A
Interior light
Livelink
B2 Instrument panel 5A
Keypads
Immobiliser
Diagnostics connection
B3 ZF ECU 7.5 A
B4 Loader ECU 20 A
B5 Management ECU 20 A
B6 Door switch 7.5 A
Engine bay lamp
219 9831/1850-4 219

Technical Data
Electrical System

B7 Trailer electrics 15 A
Radio
24/ 12 V dropper
B8 Weighload plug 10 A
B9 Radio 12 V memory 3A
B10 Radio 12 V battery 10 A
C1 24 V power socket 10 A
C2 Loader ECU 10 A
Seat switch
Main pressure sensor
Brake pressure sensor
C3 Mirror control 15 A
Rear wiper motor
C4 RH column switch 15 A
Horn
C5 Livelink 10 A
Radio
C6 Seat switch 20 A
C7 Autolube 5A
C8 **Spare** unused 5A
C9 HVAC (Heating Ventilation Air Conditioning) 15 A
C10 HVAC 5A
AC Compressor
Relays
Figure 148.
A B C D
E F G
H J K
Table 69.
Relay Circuit
A Main ignition relay 1
B Main ignition relay 2
C Spare
D Ergo traction
220 9831/1850-4 220

Technical Data
Electrical System
Relay Circuit
E Air-conditioning compressor
F Heated rear screen
G Horn
221 9831/1850-4 221

Technical Data
Engine
Engine
General

Table 70. Engine Technical Data
Manufacturer JCB Dieselmax
Code SJ
Type Turbocharged and aftercooled electronic common rail
fuel injection
Emissions standard Tier 4F
Maximum rating 81 kW
Capacity 4.4 L

Code DJ
fuel injection
Capacity 4.8 L

Code SJ
fuel injection
Capacity 4.4 L
Exhaust After Treatment (EAT)
Introduction
Your engine is equipped with an SCR (Selective Catalytic Reduction) after-treatment system. This is a fully
automated system in which DEF (Diesel Exhaust Fluid) is fed into the exhaust to remove Nitrogen Oxides. It
has a sophisticated system of self-monitoring and fault detection to ensure it is both reliable and compliant to
applicable emissions legislation.
In order that the machine can be compliant across all duty cycles the performance of the SCR must be
maintained. If a machine is used for a prolonged period ( 100 s of hours) in light duties the SCR can become
less efficient. Therefore the engine is equipped with a mode which runs the after-treatment system at typical
operating temperatures whilst the machine is being lightly used. In this way the SCR is refreshed while the
222 9831/1850-4 222

Technical Data
Engine
machine is running normally. This is automatic and seamless to the operator and the machine can continue
to be operated normally while this is happening.
Should the duty cycle continue to be very light the operator will be warned. If this occurs the operator has a
choice to either operate the machine at a higher duty or complete the refresh cycle with the machine stationary.
This again is a fully automatic process once initiated by the operator.
If the operator ignores the warnings and does not complete a stationary refresh then the SCR will cease to be
compliant and the engine will derate in accordance with the legislative requirements until a stationary refresh
has been completed.
The system has been designed such that the majority of customers should not have to invoke a stationary
refresh, however the mode exists to ensure all products remain compliant. Typically the earliest a refresh would
be required is around 700 –1,000 h.
Stationary Refresh
• The engine is equipped with a setting that will automatically run the exhaust system hot enough while
the machine is stationary. The operator will need to park the machine in a safe position and acknowledge
that the machine can run a stationary refresh by initiating the procedure. Refer to the machine operator
manual stationary refresh initiation procedure. Refer to: Instruments (Page 70).
DEF Levels
The engine or SCR will not be damaged when you run out of DEF. To protect itself the machine performance
will be reduced. Refill the DEF tank to restore performance.
The engine will not shut down if you run out of DEF, however it will:
• Give the driver a warning when the remaining level falls low, which if continually ignored will progressively
automatically reduce engine torque and reduce engine speed to tick over, preventing effective working
activity.
• Allow only enough power for ‘limp home’ i.e to move the machine to a safe area or onto a trailer.
• Restore power when the DEF tank is refilled.
Attempting to operate the machine without DEF is a Federal Offence in the United States of America, operators
may be prosecuted under the Clean Air Act.
DEF is required for type approval, operators attempting to operate the machine without DEF may be liable for
civil and criminal prosecution in the European Union.
If there are no other engine or emission system faults, the information below explains when the engine power
and speed de-ratings occur, according to DEF tank level.
Figure 149. DEF Level Warning Graph
A B C D E F
Y
A DEF level Low. Early warning to operator - Fill B DEF level indicated critical low. Last warning to
up this shift operator - Fill up now
223 9831/1850-4 223

Technical Data
Engine
C 0 % DEF level indicated on level gauge. D Engine torque will remain at the levels shown
Machine starts to derate (reduced torque) - Fill for a period - Fill up now
up now
E Engine torque begins reduce further, engine F Engine torque and engine maximum speed
maximum speed begins to reduce - Fill up now will remain at the levels shown. The engine
will no longer respond when the accelerator is
operated - Fill up now
1 Engine speed 2 Engine torque
X Percentage Y Time
Emissions System- First Fault

The presence of emissions system related faults will result in (initially) warnings given and engine power
reduction. If the warnings continue to be ignored, it will lead to the engine being only able to idle, and then
only at reduced idle power.
If the engine is shut down by the operator during these steps, unless the fault is repaired, the duration of the
step will resume from the point at which it was left.
If the fault is still detected again when the engine is restarted, the engine will continue at reduced power.
Figure 150. Emissions System First Fault Graph
A B C D E
Y
A Fault detected B Fault continues to be ignored, engine torque
reduction begins, engine maximum speed is
unaffected
C Engine torque will remain at the levels shown D Fault continues to be ignored, engine torque
for a period begins reduce further, engine maximum speed
begins to reduce
E Engine torque and engine maximum speed 1 Engine speed
will remain at the levels shown. The engine
will no longer respond when the accelerator is
operated
2 Engine torque X Percentage
Y Time
Emissions Systems Faults - Additional Faults Within 40 Hours of The First Fault
If the emissions system detects a second fault within 40 engine hours of a previous fault occurring, the system
will reduce power immediately to protect the engine, this is usually indicative of a more serious fault with the
system. The system will return to normal operation when the fault(s) are repaired.
224 9831/1850-4 224

Technical Data
Engine
Table 73. Emissions system-Faults occurring in less than 40 hours

Parameter Subsequent Fault Effects
Engine power output Initial full power further reduces to limited power at
idle speed only over time.
Engine RPM limit Reducing to idle speed only over time
Driver/operator action needed If appropriate to the application, park the machine in
a safe place. Contact your JCB engines dealer im-
mediately
DEF DO's and DON'Ts

DO's
• Before engine start up, locate and identify both separate diesel and DEF tanks, they do not share the
same tank. Do not allow cross contamination between diesel and DEF.
• Act on machine warnings that DEF is running low.
• Ensure that there is sufficient DEF in the machine at all times.
• Use only high quality DEF to ISO (International Organization for Standardization) 22241-1 from a reputable
source.
• Keep all DEF, tanks, tank necks, drums and dispensing equipment clean to prevent contamination.
DON'Ts
• Don't allow contamination of your DEF by dirt or fluid as it will damage the SCR system.
• Don't mix DEF with your diesel; it is not a fuel additive.
• Don't put DEF in your diesel tank – if you do, do not start the engine, call your JCB dealer immediately.
• Don't add chemicals to your DEF to prevent freezing.
• Don't dilute DEF with water or any other fluids or the machine may stop or be permanently damaged.
• When the engine is switched off, there is a small pump in the DEF system which purges the line from the
supply module to the dosing injector. Don't remove the battery isolator for 30 s so this operation can be
completed and the system shut down correctly. Some machines may be fitted with a power hold relay to
prevent this purge from being interrupted by operating the isolator.
225 9831/1850-4 225

Technical Data
Wheels and Tyres
Wheels and Tyres

General
The maximum pressure marked on the tyre may be different from the pressure shown below. Inflate the tyres
to the pressures shown below.
These pressures are agreed with the tyre manufacturer(s) in accordance with the ETRTO (European Tyre and
Rim Technical Organisation) standards to satisfy the machines stability performance.
If the tyres fitted to your machine are not shown, then contact your JCB dealer for advice. Do not guess the
tyre pressures.
Always check the tyre pressures with the machine in an unladen state.
In special conditions (for example on sand) the air pressure in the tyre may be reduced, refer to your JCB
dealer or tyre manufacturer.
Tyre Sizes and Pressures


Table 74.
Brand Tyre size Tyre pres- Tyre pres- Tyre pressure Tyre pressure
sure front sure rear rear with 0.5t rear with 2t hitch
hitch
Michelin XHA 15.5R25 3 bar ( 43.5 2 bar ( 29.0 2 bar ( 29.0 psi) 3.5 bar ( 50.7 psi)
psi) psi)
XTLA 15.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 3.5 bar ( 50.7 psi)
( 50.7 psi) ( 33.3 psi)
X-MINE D2 15.5R25 3 bar ( 43.5 2 bar ( 29.0 2 bar ( 29.0 psi) 3.5 bar ( 50.7 psi)
psi) psi)
XSNOPLUS 17.5R25 2.3 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 3 bar ( 43.5 psi)
( 33.3 psi) psi)
XTLA 17.5R25 2.8 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 2.5 bar ( 36.2 psi)
( 40.6 psi) psi)
XMCL 460/70R24 2.7 bar 2 bar ( 29.0 2.1 bar ( 30.4 psi) 2.9 bar ( 42.0 psi)
( 39.1 psi) psi)
XMCL 500/70R24 2.6 bar 1.9 bar 2 bar ( 29.0 psi) 2.7 bar ( 39.1 psi)
( 37.7 psi) ( 27.5 psi)
XMCL 540/70R24 2.5 bar 1.8 bar 1.9 bar ( 27.5 psi) 2.5 bar ( 36.2 psi)
( 36.2 psi) ( 26.1 psi)
Goodyear SGL 15.5x25 4 bar ( 58.0 2 bar ( 29.0 2.5 bar ( 36.2 psi) 4 bar ( 58.0 psi)
psi) psi)
HRL 15.5x25 4 bar ( 58.0 2 bar ( 29.0 2.5 bar ( 36.2 psi) 4 bar ( 58.0 psi)
psi) psi)
Nokian L GRIP 2 15.5R25 4.5 bar 3 bar ( 43.5 3 bar ( 43.5 psi) 3.6 bar ( 52.2 psi)
( 65.2 psi) psi)
L GRIP 17.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 3 bar ( 43.5 psi)
( 50.7 psi) ( 33.3 psi)
GRS 17.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 3 bar ( 43.5 psi)
( 50.7 psi) ( 33.3 psi)
Trelleborg W&T Twin Radial 600/55R26.5 2.8 bar 1.3 bar 1.6 bar ( 23.2 psi) 2.5 bar ( 36.2 psi)
( 40.6 psi) ( 18.8 psi)
226 9831/1850-4 226

Technical Data
Wheels and Tyres

Table 75.
hitch
Michelin XSNOPLUS 17.5R25 2.3 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 3 bar ( 43.5 psi)
( 33.3 psi) psi)
XTLA 17.5R25 2.8 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 2.5 bar ( 36.2 psi)
( 40.6 psi) psi)
XMCL 460/70R24 2.7 bar 2 bar ( 29.0 2.1 bar ( 30.4 psi) 2.9 bar ( 42.0 psi)
( 39.1 psi) psi)
( 37.7 psi) ( 27.5 psi)
XMCL 540/70R24 2.5 bar 1.8 bar 1.9 bar ( 27.5 psi) 2.5 bar ( 36.2 psi)
( 36.2 psi) ( 26.1 psi)
Nokian L GRIP 2 15.5R25 4.5 bar 3 bar ( 43.5 3 bar ( 43.5 psi) 3.6 bar ( 52.2 psi)
( 65.2 psi) psi)
L GRIP 17.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 3 bar ( 43.5 psi)
( 50.7 psi) ( 33.3 psi)
GRS 17.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 3 bar ( 43.5 psi)
( 50.7 psi) ( 33.3 psi)
( 40.6 psi) ( 18.8 psi)

Table 76.
hitch
Michelin XHA 17.5R25 3 bar ( 43.5 2 bar ( 29.0 2 bar ( 29.0 psi) 2.5 bar ( 36.2 psi)
psi) psi)
XHA 20.5R25 3.3 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 3 bar ( 43.5 psi)
( 47.8 psi) psi)
XTLA 17.5R25 3.5 bar 2.3 bar 2.3 bar ( 33.3 psi) 2.5 bar ( 36.2 psi)
( 50.7 psi) ( 33.3 psi)
XSNOPLUS 17.5R25 3 bar ( 43.5 2 bar ( 29.0 2 bar ( 29.0 psi) 2.5 bar ( 36.2 psi)
psi) psi)
X-MINE D2 17.5R25 3 bar ( 43.5 2 bar ( 29.0 2 bar ( 29.0 psi) 3 bar ( 43.5 psi)
psi) psi)
( 40.6 psi) ( 27.5 psi)
XM27 620/70R26 1.6 bar 1.1 bar 1.1 bar ( 15.9 psi) N/A
( 23.2 psi) ( 15.9 psi)
MEGA XBIB 620/75R26 1.6 bar 1.1 bar 1.2 bar ( 17.4 psi) 2.2 bar ( 31.9 psi)
( 23.2 psi) ( 15.9 psi)
MEGA XBIB 750/50R26 1.8 bar 1.3 bar 1.3 bar ( 18.8 psi) 2.5 bar ( 36.2 psi)
( 26.1 psi) ( 18.8 psi)
CEREXBIB 620/70R26 2 bar ( 29.0 1.5 bar 1.5 bar ( 21.7 psi) 1.5 bar ( 21.7 psi)
psi) ( 21.7 psi)
Bibload 460/70 R24 2.7 bar 2 bar ( 29.0 - -
( 39.1 psi) psi)
Bibload 500/70 R24 2.6 bar 1.9 bar - -
( 37.7 psi) ( 27.5 psi)
227 9831/1850-4 227

Technical Data
Wheels and Tyres
hitch
Goodyear SGL 17.5x25 4.3 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 3.5 bar ( 50.7 psi)
( 62.3 psi) psi)
HRL 17.5x25 4.5 bar 2 bar ( 29.0 2 bar ( 29.0 psi) 3.5 bar ( 50.7 psi)
( 65.2 psi) psi)
Nokian L GRIP 17.5R25 4 bar ( 58.0 2.5 bar 2.5 bar ( 36.2 psi) 3 bar ( 43.5 psi)
psi) ( 36.2 psi)
BKT XL GRIP 17.5x25 2.8 bar 2.5 bar 2.5 bar ( 36.2 psi) 2.5 bar ( 36.2 psi)
( 40.6 psi) ( 36.2 psi)
( 46.4 psi) ( 20.3 psi)
Bridge- VSW 17.5R25 4 bar ( 58.0 2.5 bar 2.8 bar ( 40.6 psi) 3.3 bar ( 47.8 psi)
stone psi) ( 36.2 psi)
VSW 20.5R25 3.3 bar 2 bar ( 29.0 2.3 bar ( 33.3 psi) 3 bar ( 43.5 psi)
( 47.8 psi) psi)
Alliance A690GSR 25 km/h ( 15.5 3.5 bar 3.5 bar 4.5 bar ( 65.2 psi) 4.5 bar ( 65.2 psi)
mph) ( 50.7 psi) ( 50.7 psi)
A690GSR 40 km/h ( 24.9 4.25 bar 4.25 bar 4.5 bar ( 65.2 psi) 4.5 bar ( 65.2 psi)
mph) ( 61.6 psi) ( 61.6 psi)
A690GSR 50 km/h ( 31.1 4.5 bar 4.5 bar 4.5 bar ( 65.2 psi) 4.5 bar ( 65.2 psi)
mph) ( 65.2 psi) ( 65.2 psi)
228 9831/1850-4 228

Technical Data
General
A completed copy of the EC Declaration of Conformity is supplied with all machines manufactured according
to EC type examination and/or self-certification requirements.
A sample copy of the EC Declaration of Conformity and a summary of the information that can appear is
provided. Refer to: Data (Page 229).
Data
Table 77.
A JCB Earthmovers, Leek Road, Cheadle, Stoke-on-Trent, ST10 2JX.
B Loaders (Wheeled).
C Refer to: Model and Serial Number (Page 1).
D Refer to: Machine (Page 10).
E EN 474-1:2006+A1:2009, EN 474-4:2006 +A1:2009.
F Engineering Manager, Earthmovers, Harewood Estate, Leek Road, Cheadle, Stoke-on-Trent,
ST10 2JX.
G Earthmovers, Leek Road, Cheadle, Stoke-on-Trent, ST10 2JX.
H ANNEX VI PROCEDURE 1.
J A. V. Technology, A. V. House, Birdhall Lane, Stockport, Cheshire, United Kingdom, SK3 0XU.
K Refer to: Noise Data (Page 204).
L Refer to: Noise Data (Page 204).
M Rocester.
N Managing Director.
P Loader.
229 9831/1850-4 229

Technical Data
Figure 151.
230 9831/1850-4 230

Technical Data
Service Record Sheet
Table 78.
Date Annual Insurance (Yes)
Hours Signature and stamp
Figure 152. Installation Checklist
/ / h
Figure 153. 500h/3 Month
/ / h
/ / h
231 9831/1850-4 231

Technical Data
/ / h
/ / h
/ / h
/ / h
232 9831/1850-4 232

Technical Data
/ / h
/ / h
/ / h
Figure 162. 5000h/30Month
/ / h
233 9831/1850-4 233

Technical Data
/ / h
/ / h
/ / h
/ / h
234 9831/1850-4 234

Technical Data
/ / h
/ / h
/ / h
/ / h
235 9831/1850-4 235

Technical Data
/ / h
/ / h
/ / h
/ / h
236 9831/1850-4 236

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OPERATOR'S MANUAL

EN - 9831/1850 ISSUE 4 - 03/2018

THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

You and others can be killed or seriously injured

OPERATOR'S Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADER Machine Delivery and Installation

Following the installation you will know how to gain

Please contact your local JCB dealer if the

Your local JCB Dealer is

EN - 9831/1850 - ISSUE 4 - 03/2018

This manual contains original instructions, verified by

Copyright 2018 © JCB SERVICE

Find manuals at https://best-manuals.com

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Contents Page No.

Acronyms Glossary ........................................................................................................................................ vii

About the Product

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Driving on Slopes ............................................................................................................................... 79

iii 9831/1850-4 iii

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Preservation and Storage

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ARV Auxiliary Relief Valve

vii 9831/1850-4 vii

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viii 9831/1850-4 viii

Using the Manual

Left-Hand Side, Right-Hand Side

A Manual location B Operator seat

Figure 3. The safety alert system symbol

Clothing and Personal Protective Equipment (PPE)

About the Product

Name and Address of the Manufacturer

Log Moving/Object Handling

Optional Equipment and Attachments

Before you do a maintenance task, make the product safe.

Main Component Locations

A Loader arms B Quickhitch (option)

Product and Component Identification

A Identification plate (location)

Table 1. Typical PIN

Table 2. Explanation of the PIN

The data label includes the engine identification number.

Table 3. Example of the engine identification number

Table 5. Explanation of the engine identification number

Operator Protective Structure

There are two levels of FOPS:

Safety Label Identification

Table 6. Safety Labels

Item Part No. Description Qty.

Table 7. Switch positions

Single Speed (Standard)

Two Speed (Optional)