446,456 Operators Manual

www.WorkshopManuals.co.
uk
JCB Service
World Parts Centre
Operator Waterloo Park

Uttoxeter
ST14 5PA, England
Tel. 01889 - 590312
Handbook Produced by the Technical

Publications Department of
JCB Service
446 456ZX 456HT
! THIS HANDBOOK MUST BE KEPT IN THE MACHINE AT ALL TIMES !

Publication Number 9801/8710 Aug 2002 Issue 2
Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

SAFETY NOTICES
In this handbook and on the machine there are safety notices. Each notice starts
with a signal word. The meanings of the signal words are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is
highly probable that the operator (or others) could be killed or seriously
injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator
(or others) could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety
practices could result in injury to the operator (or others) and possible
damage to the machine.
INT-1-2-3
! WARNING
Study This Handbook Before Starting The Machine
You must understand and follow the instructions in this handbook. You must
observe all relevant laws and regulations. If you are unsure about anything, ask your
JCB distributor or employer. Do not guess, you or others could be killed or
seriously injured.
INT-1-1-1
! CAUTION
Do not fit an attachment to this machine which is not JCB approved. Consult your
JCB distributor before fitting any non approved attachment.
8-4-1-6
MACHINE SECURITY
Vandalism and theft of unattended machines is an ever increasing problem and

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

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

these sensible precautions. ACT NOW!
INT-1-2-4
8710-1

i
CONTENTS i
Page Page
INTRODUCTION Display Panel

Ignition On ............................................................. 35
About this Handbook Pre-Start Mode ..................................................... 35
Machine Models and Serial Number ................... 1 Setting Up ............................................................. 35
Using this Handbook . ......................................... 1 Start Inhibit ............................................................ 35
Units of Measurement ......................................... 1 Warning Lights ...................................................... 36
Page Numbering ................................................. 1 Visual Warning and Message ................................. 37
Left Side, Right Side . .......................................... 1 Automatic Engine Shut Down ............................... 37
Using the Machine .............................................. 1 Segmented Displays ............................................. 37
Page Cross Reference .......................................... 1 Master Warning Light ............................................ 37
Indications (Engine Off) ......................................... 38
The JCB Wheeled Loader Indications (Engine Running) ................................ 38
Machine Description . ......................................... 2
Warning Light Test .............................................. 38
Safety First - Yours and Other People's . ........ 3
Heater/Air Conditioning Controls ...................... 39
Safety Check List
General Safety .................................................... 3 Loader Controls
Operating Safety ................................................. 4 Standard Shovel ................................................. 40
Maintenance Safety ............................................ 5 Adjusting the Loader Arm Preset Height (456HT) .. 41
Testing the Loader Arm Preset Height (456HT) ... 41
Safety Decals ..................................................... 7 Adjusting the Shovel Preset Angle (456HT) ........... 41
Testing the Shovel Preset Angle (456HT) ............ 41
Identifying Your Machine Adjusting the Loader Arm Preset Height
Machine Identification Plate ................................ 8 (446 & 456ZX) ... 42
Unit Identification . ............................................... 8 Testing the Loader Arm Preset Height
(446 & 456ZX .. 42
Adjusting the Shovel Preset Angle
OPERATION (446 & 456ZX .... 42
Testing the Shovel Preset Angle
Introduction ....................................................... 21 (446 & 456ZX .. 42
Before Entering the Cab ................................... 21 Before Starting the Engine ............................... 43
Entering/Leaving the Cab ................................... 22 Starting the Engine ........................................... 45
Door and Windows Jump-Starting the Engine . ............................... 46

Opening and Closing the Door ............................ 23
Opening and Closing the Side Windows .............. 23 Travelling Position
Emergency Exit ..................................................... 23 On Site ............................................................... 48
On Public Roads ................................................. 48
Seat Adjustment ................................................ 24 Automatic Carry Control System - ACCS (If fitted) 48
Seat Belt Getting the Machine Moving

Fastening the Seat Belt ....................................... 25 Operating Hints ................................................... 49
Releasing the Seat Belt ....................................... 25
Checking Seat Belt is Operating Correctly . ........ 25 Stopping and Parking the Machine . ................ 50
Cab Layout ........................................................ 26 Testing the Parking Brake ................................ 51
Controls, Switches and Instruments Using the Attachments and Site Safety . ......... 52
Controls . ............................................................. 27
Switches ............................................................... 30 Operating in Low Temperatures ...................... 54
Steering Wheel Tilt Adjustment ............................. 33 Transmission Cold Start Procedure......................... 54
Cab Interior Light .................................................. 33
Battery Isolator Switch .......................................... 34 Operating in High Temperatures ..................... 54
Loader Control Lock ........................................... 34 Moving a Disabled Machine ............................ 55
Transporting the Machine .................................. 56
8710-2

ii
CONTENTS ii
Page Page
Lifting the Machine ............................................. 57 Seat Belt
Checking Seat Belt Security and Condition ........ 82
Fire Extinguisher ................................................. 58 Cab Heater/Filter
Cleaning the Intake Filter ...................................... 83
Recovery Hitch .................................................... 58 Cleaning the Recirculation Filter ............................ 83
Height Restriction System ................................. 59 Engine Air Filter

Changing the Elements ........................................ 84
MAINTENANCE Engine Oil and Filter
Checking the Oil Level ........................................ 85
Lubricants - Health and Safety Changing the Oil and Filter ................................. 86
Hygiene ............................................................... 71
Storage ............................................................... 71 Engine Cooling System
Waste Disposal ................................................... 71 Checking the Coolant Level ................................ 87
Handling .............................................................. 71 Coolant Mixtures ................................................. 87
First Aid - Oil ....................................................... 71 Anti-corrosion Additives ....................................... 87
Spillage ............................................................... 71 Draining and Refilling the Coolant ...................... 88
Fires .................................................................... 71 Changing the Coolant Filter .................................. 89
Service Requirements Engine Drive Belt ................................................. 90

Introduction .......................................................... 72
Maintenance ......................................................... 72 Air Conditioning Compressor Drive Belt
Owner/Operator Support ...................................... 72 Adjusting the Compressor Belt ........................... 91
Service/Maintenance Agreements ........................ 72
Fuel System
General Safety ..................................................... 73 Types of Fuel . ..................................................... 92
Fuel Standards .................................................... 92
Service Schedules ............................................... 73 Low Temperature Fuels . ..................................... 92
Filling the Tank .................................................... 92
Articulation Lock Draining the Fuel Filter . ......................................... 93
Installing and Removing the Articulation Lock ..... 75 Changing the Fuel Filter Element ......................... 93
Draining the Sedimenter Bowl .............................. 94
Loader Arm Safety Strut Cleaning the Sedimenter Bowl ............................. 94
Installing and Removing the Safety Strut .............. 76 Bleeding the Fuel System ..................................... 95
ROPS/FOPS Structure Transmission

Checking the ROPS/FOPS Structure ................. 77 Checking the Oil Level .......................................... 96
Changing the Oil & Filter ........................................ 96
Brakes (446 Only)
Adjusting the Parking Brake .................................. 77 Front and Rear Axles
Checking the Differential Oil Level ........................ 97
Engine Covers Draining and Refilling the Differential Oil .............. 97
Opening and Closing the Engine Covers ............. 78 Checking the Hub Oil Level .................................. 98
Draining and Refilling the Hub Oil ......................... 98
Rear Grille
Opening and Closing the Rear Grille .................... 78 Hydraulic System ...................................................
Checking the Fluid Level ..................................... 99
Greasing Hydraulic Tank Cap ............................................... 99
Shovel Pivot Pins ................................................ 79 Changing the Filter Element .................................. 100
Loader Arm Pivot Points ..................................... 79
Centre Pivot and Steering Ram . ......................... 80 Battery
Rear Axle Pivots .................................................... 80 Warning Symbols ................................................... 101
Propshafts ............................................................. 81 First Aid ................................................................ 102
Cab Door Hinges ................................................... 81 Checking Electrolyte Level ..................................... 102
Checking for Damage ....................................... 82 Electrical System

Fuses .................................................................... 103
Cleaning the Machine ....................................... 82 Primary Fuses & Relays ........................................... 104
Bulbs ................................................................... 105
8710-2

iii
CONTENTS iii
Page
Windscreen Washer .......................................... 105
Tyres and Wheels

Inflating the Tyres ................................................ 106
Checking the Wheel Nut Torques ....................... 106
Fluids, Capacities and Lubricants ................... 107
Fire Extinguisher
Checking the Fire Extinguisher ............................. 108
Obtaining Replacement Parts .......................... 108
OPTIONAL ATTACHMENTS
Introduction ....................................................... 131
SPECIFICATION
Lifting (Craning) Regulations and Safe Working Loads

Lifting Regulations ................................................ 151
Safe Working Loads .............................................. 151
Loader Unit ........................................................... 151
Tyre Pressures .................................................... 151
Working Capacity ................................................ 152
Static Dimensions ............................................... 153
Noise and Vibration Data ................................. 154
SERVICE RECORD SHEET ............... At back of book
8710-2

1
INTRODUCTION 1
ABOUT THIS HANDBOOK
Machine Model and Serial Number

Using the machine
This handbook provides information for the following
models in the JCB Wheeled Loader Range: To use the JCB Wheeled Loader efficiently and safely you
must know the machine and have the skill to use it. This
446 From Serial Number 540050 handbook instructs you on the machine, its controls and
456ZX From Serial Number 539400 its safe operation. It is not a training manual on the art of
456HT From Serial Number 539433 loading. If you are a new operator, get yourself trained in
the skills of using a JCB Wheeled Loader before trying to
work with it. If you don't, you will not do your job well, and
Using this Handbook you will be a danger to yourself and others.
The illustrations used in this handbook are for guidance Page Cross References
only. Where the machines differ, the text and/or the
illustration will specify. In this handbook, page cross references are made by
presenting the subject followed by the section containing
This handbook is arranged to give you a good the subject. The letters are printed in bold and italic to
understanding of the machine and its safe operation. It signify that they are cross references - for example:
also contains maintenance information and specification
data. Read this handbook from front to back before using 1 Raise and Lock the Loader Arms.
the machine for the first time. Particular attention must be
given to all the safety aspects of operating and See Loader Arm Safety Strut
maintaining the machine. (MAINTENANCE section).
General warnings in this chapter are repeated throughout Use the section contents list at the beginning of the book
the book, as well as specific warnings. Read all the safety to find the exact page number.
statements regularly, so you do not forget them.
Remember that the best operators are the safest
operators.
Finally, treat this handbook as part of the machine. Keep it

clean and in good condition. Do not operate the machine
without a handbook in the cab. If there is anything you are
not sure about, ask your JCB distributor or employer. Do
not guess, you or others could be killed or seriously
injured.
The manufacturer's policy is one of continuous

improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
INT-1-2-5/1
Units of measurement
In this handbook, the S.I. system of units is used. For
example, liquid capacities are given in litres. The Imperial
units follow in parenthesis () eg 28 litres (6 gal).
Page numbering
The page numbering system in this handbook is not
continuous. There is a gap of about ten pages between
sections. This allows for the insertion of new pages in later
issues of the handbook.
Left Side, Right Side

In this handbook, 'left' and 'right' mean your left and right
when you are seated correctly in the machine.
8710-2

2
INTRODUCTION 2
THE JCB WHEELED LOADER
MACHINE DESCRIPTION
Loader: Self-propelled wheeled machine with an integral front mounted shovel-supporting structure and linkage, which
loads or excavates through forward motion of the machine, and lifts, transports and discharges material.
Component Locations
1 Engine Oil Level Dipstick

2 Hydraulic Fluid Filler
3 Hydraulic Fluid Tank Sight Glass
4 Tool Stowage Box
5 Transmission Oil Level Dipstick
6 Diesel Filler
7 Articulation Lock
8 Battery/Isolator
7
8
397110
1
2
6
397120
8710-1

3
INTRODUCTION 3
SAFETY FIRST - YOURS AND OTHER PEOPLES
All construction and agricultural equipment can be ! WARNING

hazardous. When a JCB Wheeled Loader is correctly Decals
operated and properly maintained, it is a safe machine to You can be injured if you do not obey the decal safety
work with. But when it is carelessly operated or poorly instructions. Keep decals clean. Replace unreadable or
maintained it can become a danger to you (the operator) missing decals with new ones before operating the
and others. machine. Make sure replacement parts include warning
decals where necessary.
In this handbook and on the machine you will find warning INT-1-3-4
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not ! WARNING
fully understand the warning messages, ask your Care and Alertness
employer or JCB distributor to explain them. All the time you are working with or on the machine, take
care and stay alert. Always be careful. Always be alert for
But safety is not just a matter of responding to the hazards.
INT-1-3-5
warnings. All the time you are working on or with the
machine you must be thinking what hazards there might ! WARNING
be and how to avoid them Clothing
You can be injured if you do not wear the proper clothing.
Do not work with the machine until you are sure that you Loose clothing can get caught in the machinery. Wear
can control it. protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a
Do not start any job until you are sure that you and those well fitting overall, ear-protectors and industrial gloves.
around you will be safe. Keep cuffs fastened. Do not wear a necktie or scarf. Keep
long hair restrained.
If you are unsure of anything, about the machine or the INT-1-3-6
job, ask someone who knows. Do not assume anything.
! WARNING
Raised Attachments
Remember
Raised attachments can fall and injure you. Do not walk or
work under raised attachments unless they are safely
BE CAREFUL
blocked.
BE ALERT
INT-1-3-8
BE SAFE
INT-1-3-1/1 ! WARNING
Alcohol and Drugs
SAFETY FIRST - CHECK LIST It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not consume
General Safety alcoholic drinks or take drugs before or whilst operating
the machine or attachments. Be aware of medicines which
! WARNING can cause drowsiness.
INT-1-3-9
Handbook
You and others can be injured if you operate or maintain
the machine without first studying this handbook. Read ! WARNING
the safety instructions before operating the machine. If Machine Modifications
you do not understand anything, ask your employer or This machine is manufactured in compliance with
JCB distributor to explain it. Keep this handbook clean legislative and other requirements. It should not be altered
and in good condition. Do not operate the machine in any way which could affect or invalidate any of these
without a handbook in the cab, or if there is anything on requirements. For advice consult your JCB Distributor.
the machine you do not understand.
INT-1-3-2 Reference should also be made to Optional Attachments
section where appropriate.
! CAUTION INT-1-3-10
Regulations
Obey all laws, work site and local regulations which affect
you and your machine.
INT-1-3-3
8710-1

4
INTRODUCTION 4
SAFETY - CHECK LIST

(continued)
Operating Safety
! WARNING ! WARNING
Practice Hazardous Atmospheres
You or others can be killed or seriously injured if you do This machine is designed for use in normal out door
unfamiliar operations without first practicing them. atmospheric conditions. It should not be used in an
Practice away from the work site on a clear area. Keep enclosed area without adequate ventilation. Do not use
other people away. Do not perform new operations until the machine in a potentially explosive atmosphere, i.e.
you are sure you can do them safely. combustible vapours, gas or dust, without first consulting
INT-2-1-1 your JCB Distributor.
INT-2-1-14
! WARNING
Machine Condition ! WARNING
A defective machine can injure you or others. Do not Passengers
operate a machine which is defective or has missing parts. Passengers in or on the machine can cause accidents.
Make sure the maintenance procedures in this handbook The JCB Wheeled Loader is a one man machine. Do not
are completed before using the machine. carry passengers.
INT-2-1-2 INT-2-2-2
! WARNING ! WARNING
Controls Parking
You or others can be killed or seriously injured if you An incorrectly parked machine can move without an
operate the control levers from outside the cab. Operate operator. Follow the instructions in this handbook to park
the control levers only when you are correctly seated the machine correctly.
inside the cab. INT-2-2-4
INT-2-1-3
! DANGER
! WARNING
Machine Limits Sparks
Operating the machine beyond its design limits can Explosions and fire can be caused by sparks from the
damage the machine, it can also be dangerous. Do not exhaust or the electrical system. Do not use the machine
operate the machine outside its limits. Do not try to in closed areas where there is flammable material, vapour
upgrade the machine performance with unapproved or dust.
INT-2-2-10
modifications.
INT-2-1-4
! WARNING
! WARNING Safe Working Loads
Exhaust Gases Overloading the machine can damage it and make it
Breathing the machine exhaust gases can harm and unstable. Study the lifting and/or digging specifications in
possibly kill you. Do not operate the machine in closed this handbook before using the attachments.
INT-2-2-11/1
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
INT-2-1-10
! WARNING
Visibility
Accidents can be caused by working in poor visibility.
Keep windows clean and use your lights to improve
visibility. Do not operate the machine if you cannot see
properly.
INT-2-1-11
8710-1

5
INTRODUCTION 5
SAFETY - CHECK LIST

(continued)
Maintenance Safety
! WARNING ! WARNING
Repairs Soft Ground
Do not try to do repairs or any other type of maintenance A machine can sink into soft ground. Never work under a
work you do not understand. Get a Service Manual from machine on soft ground.
your JCB distributor, or get the work done by a specialist INT-3-2-4
engineer.
INT-3-1-1 ! WARNING
Counterweights
! WARNING Your machine may be fitted with counterweights. They are
Modifications and Welding extremely heavy. Do not attempt to remove them.
Non-approved modifications can cause injury and INT-3-2-5
damage. Parts of the machine are made of cast iron;
welds on cast iron can weaken the structure and break.
! WARNING
Fires
Do not weld cast iron. Contact your JCB distributor for
If your machine is equipped with a fire extinguisher, make
advice before modifying the machine
INT-3-1-2/1
sure it is checked regularly. Keep it in the operator's cab
until you need to use it.
! WARNING
Metal Splinters Do not use water to put out a machine fire, you could
You can be injured by flying metal splinters when driving spread an oil fire or get a shock from an electrical fire. Use
metal pins in or out. Use a soft faced hammer or drift to carbon dioxide, dry chemical or foam extinguishers.
remove and fit metal pins. Always wear safety glasses. Contact your nearest fire department as quickly as
INT-3-1-3 possible.
! WARNING Firefighters should use self-contained breathing
Electrical Circuits
apparatus.
Understand the electrical circuit before connecting or INT-3-2-7/1
disconnecting an electrical component. A wrong
connection can cause injury and/or damage. ! WARNING
INT-3-1-4 Jacking
A machine can roll off jacks and crush you unless the
! WARNING wheels have been chocked. Always chock the wheels at
Communications
the opposite end of the machine that is to be jacked. Do
Bad communications can cause accidents. If two or more
not work underneath a machine supported only by jacks.
people are working on the machine, make sure each is
Always support a jacked-up machine on axle stands
aware of what the others are doing. Before starting the
before working underneath it.
engine make sure the others are clear of the danger areas; INT-3-2-8
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and ! WARNING
anywhere beneath or behind the machine. People can be Rams
killed or injured if these precautions are not taken. The efficiency of the rams will be affected if they are not
INT-3-1-5 kept free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
! WARNING rams if possible to reduce the risk of weather corrosion.
Hydraulic Pressure INT-3-2-10
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the ! CAUTION
engine and operate the controls to release pressure
Cleaning
trapped in the hoses. Make sure the engine cannot be
Cleaning metal parts with incorrect solvents can cause
started while the hoses are open.
INT-3-1-11/1
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
8710-1

6
INTRODUCTION 6
SAFETY - CHECK LIST

(continued)
! CAUTION ! WARNING
'O' rings, Seals and Gaskets Fluoroelastomeric Materials
Badly fitted, damaged or rotted 'O' rings, seals and Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
gaskets can cause leakages and possible accidents. machines contain fluoroelastomeric materials such as
Renew whenever disturbed unless otherwise instructed. Viton, Fluorel and Technoflon. Fluoroelastomeric materials
Do not use Trichloroethane or paint thinners near 'O' rings subjected to high temperatures can produce highly
and seals. corrosive hydrofluoric acid. THIS ACID CAN SEVERELY
INT-3-2-12 BURN.
! WARNING New fluoroelastomeric components at ambient

Fire Extinguishers temperature require no special safety precautions.
If your machine is equipped with a fire extinguisher, make
sure it is checked regularly by suitably qualified personnel. Used fluoroelastomeric components whose temperatures
Keep it in the operator's cab until you need to use it. have not exceeded 300°C require no special safety
INT-3-3-1
precautions. If evidence of decomposition (e.g. charring) is
! WARNING found, refer to the next paragraph for safety instructions
Hydraulic Hoses DO NOT TOUCH COMPONENT OR SURROUNDING
Damaged hoses can cause fatal accidents. Inspect the AREA.
hoses regularly for:
Damaged end fittings Used fluoroelastomeric components subjected to
Chafed outer covers temperatures greater than 300°C (e.g. engine fire) must be
Ballooned outer covers treated using the following safety procedure. Make sure
Kinked or crushed hoses that heavy duty gloves and special safety glasses are
Embedded armouring in outer covers worn:
Displaced end fittings.
INT-3-3-2 1 Ensure that components have cooled then remove and
place material into plastic bags.
! WARNING
Raised Machine 2 Thoroughly wash contaminated area with 10% calcium
NEVER position yourself or any part of your body under a hydroxide or other suitable alkali solution, if necessary
raised machine whch is not properly supported. If the use wire wool to remove burnt remains.
machine moves unexpectedly you could be trapped and
suffer serious injury or be killed. 3 Thoroughly wash contaminated area with detergent
INT-3-3-7/1
and water.
! WARNING
Working under the Machine 4 Contain all removed material, gloves etc. used in this
Make the machine safe before getting beneath it. Ensure operation in sealed plastic bags and dispose of in
that any fitments on the machine are secure; engage the accordance with Local Authority Regulations.
parking brake, remove the starter key, disconnect the
battery. DO NOT BURN FLUOROELASTOMERIC MATERIALS.
INT-3-3-8
If contamination of skin or eyes occurs, wash the affected
area with a continuous supply of clean water or with
calcium hydroxide solution for 15-60 minutes. Get medical
attention immediately.
INT-3-3-5/1
8710-1

7
INTRODUCTION 7
SAFETY DECALS
! WARNING ! WARNING
Decals on the machine warn you of particular hazards. If you need eye-glasses for reading, make sure you wear
Each decal is attached close to a part of the machine them when reading the safety decals. Decals are
where there is a possible hazard. Read and make sure you strategically placed around the machine to remind you of
understand the safety message before you work with or possible hazards. Do not over-stretch or place yourself in
on that part of the machine. dangerous positions to read the decals.
INT-3-3-4
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment points
! WARNING
Keep all decals clean and readable. Replace lost or
are shown on the following pages. Each decal has a part
damaged decals. The decals and their attachment points
number printed on it, use this number to order a new
are shown on the following pages. Each decal has a part
decal from your JCB distributor.
INT-3-3-3
number printed on it, use this number to order a new
decal from your JCB distributor.
INT-3-3-6
WARNING
DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS
YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS
AND WARNINGS IN THE OPERATION AND MAINTENANCE
MANUAL. FAILURE TO FOLLOW THE INSTRUCTIONS OR
HEED THE WARNINGS COULD RESULT IN INJURY OR
DEATH
CONTACT ANY J.C.B. DEALER FOR REPLACEMENT COPIES.
PROPER CARE IS YOUR RESPONSIBILITY
397130
Note: The labels illustrated are in English. Your JCB Distributor will advise you on the availability of labels in other languages.
8710-1

8
INTRODUCTION 8
IDENTIFYING YOUR MACHINE
Identification Plate
Your machine has an identification plate T located as
shown. The serial numbers of the machine, engine and
transmission unit are stamped on the plate.
Unit Identification
The machine, engine and transmission serial numbers
identify exactly the type of equipment you have.
If the engine or transmission is replaced by a new one, the

serial number stamped on the identification plate will be
wrong. Either stamp the new number onto the plate or
stamp out the old one.
The engine serial number is stamped on a plate W on the

right hand side of the cylinder block.
The axle serial number is stamped on a plate mounted on

the axle arm casing. This is applicable to both front and
rear axle.
The transmission serial number is stamped on a plate X

mounted on the side of the unit. W
397080
397140
X A337470
8710-1

21
OPERATION 21
INTRODUCTION
The aim of this part of the handbook is to guide the When you have familiarised yourself with the operating
operator step-by-step through the task of learning how to controls, gauges and switches, practice using them. Drive
operate the machine efficiently and safely. Read the the machine in an open space, clear of people. Get to
OPERATION section through from beginning to end. know the 'feel' of the machine and its driving controls.
Before starting the machine, sit in the driver's seat and

familiarise yourself with the layout of the cab. Use your Finally, do not rush the job of learning, make sure you fully
handbook to identify each control lever, switch, gauge, understand everything in the OPERATION section. Take
button and pedal. Do not guess. If there is anything you your time and work efficiently and safely.
do not understand, ask your JCB distributor.
Remember
The operator must always be aware of events happening
outside the cab as well as inside the cab. Safety must BE CAREFUL
always be the most important feature when operating the BE ALERT
Wheeled Loader. BE SAFE
BEFORE ENTERING THE CAB
The following checks should be made each time you 1 Check for Cleanliness
return to the machine after leaving it for any period of time.
We advise you also to stop the machine occasionally a Clean the windows, light lenses and rear view
during long work sessions and do the checks again. mirrors.
All these checks concern the serviceability of the machine. b Remove dirt and debris, especially from around
Some concern your safety. Get your service engineer to the linkages, rams, pivot points and radiator.
check and correct any defects.
c Make sure the cab step and handholds are clean
! WARNING and dry.
Walking or working under raised attachments can be
hazardous. You could be crushed by the attachments d Clean all safety decals. Replace any that are
or get caught in the linkages. missing or cannot be read.
Lower the attachments to the ground before doing 2 Check for Damage
these checks. If you are new to this machine, get an
experienced operator to lower them for you. a Inspect the machine generally for damaged and
missing parts.
If there is nobody to help you, study this handbook
until you have learned how to lower the attachments. b Make sure that the bucket is secure and in good
Also make sure that the parking brake is engaged condition.
before doing these checks.
2-2-1-1 c Make sure that all pivot pins are secured correctly
in place.
d Inspect the windows for cracks and damage.

Glass splinters can blind you.
e Check for oil, fuel and coolant leakages

underneath the machine.
8710-1

22
OPERATION 22
BEFORE ENTERING THE CAB

(continued)
! 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.
2-2-1-2
3 a Make sure the tyres are correctly inflated. See 4 a Make sure the engine canopy catch is secure.
Inflating the Tyres in MAINTENANCE section for a
safe procedure for inflating the tyres. b Make sure the fuel filler cap is tightly closed. (We
also recommend that, if possible, you lock the filler
b Check for cut rubber and penetration by sharp cap.)
objects. Do not use a machine with damaged
tyres.
ENTERING & LEAVING THE CAB
! WARNING
Entering/Leaving
Entering or leaving the cab or canopy must only be Use the handholds A when entering or leaving the cab. Do
made where steps and handrails are provided. Always not use the steering wheel as a handhold.
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
use the machine controls as handholds, use the
handrails.
INT-2-1-7/1
A
A A A A
A A A
A A
S271660
8710-1

23
OPERATION 23
DOORS AND WINDOWS
Opening and Closing the Door Emergency Exit (Not illustrated)

To open a door from the outside, unlock it with the key In an emergency, if the door cannot be used; using the
provided and press the lock barrel. emergency glazing breaker, strike the rear window near a
corner, this will shatter the window which can then be
Close the door from the inside by pulling it firmly; it will kicked out.
latch itself.
To open the door from inside, pull lever A towards the

rear. The door is opened by a gas strut.
Opening and Closing the Side Windows

To open a side window, operate both latches B, slide
window until the window locks into the required position.
B
A
S269970 S269970
8710-1

24
OPERATION 24
SEAT ADJUSTMENT
The operator's seat can be adjusted for your comfort. A

correctly adjusted seat will reduce operator fatigue.
Position the seat so that you can comfortably reach the
controls. Adjust the seat so that you can depress the
brake pedal fully with your back against the backrest.
Height (front)
1 Lift handle B upwards and raise or lower the front of

the seat cushion to required height (there are five
settings).
2 Release handle B at required height adjustment,

make sure the seat has locked into position.
Height (rear)
1 Lift handle C upwards and raise or lower the rear of

the seat cushion to required height (there are five
settings).
2 Release handle C at required height adjustment,

make sure the seat has locked into position.
Fore/Aft
1 Lift handle D upwards and slide the seat forwards or

backwards to the required position.
2 Release handle D, make sure the seat has locked into

position.
Backrest Angle
1 Sit in the seat and press your back firmly against the
backrest.
2 Pull lever E, and put the backrest to the angle you

want.
3 Release lever E, make sure the backrest has locked

into position.
Weight
1 Sit in the seat and turn dial F so that your weight (in
kilograms) shows in the red sector. This will adjust
the seat suspension to suit your weight. E
B C
F
D
S201760
8710-1

25
OPERATION 25
SEAT BELT
Fastening the Seat Belt Releasing the Seat Belt

1 Sit correctly in the seat. Pull the belt from its reel 1 Press button C and pull the male fitting A from the
holder in one continuous movement. buckle.
2 Push the male fitting A into the buckle B until it 2 Let the seat belt retract into its reel holder.
latches into position. Make sure the seat belt is not
twisted and that it is over your hips not your stomach. Checking the Seat Belt is Operating
Correctly
Note: If the belt 'locks' before the male fitting A has been
engaged, allow the belt to fully retract in its reel holder and 1 Sit correctly in the seat and fasten the seat belt as
then try again. described.
! WARNING 2 Take hold of the seat belt and tug. The seat belt
The ROPS cab is designed to give you protection in an
should 'lock'. If the seat belt does not 'lock', get the
accident. If you do not wear your seat belt you could
seat belt repaired or replaced.
be thrown about inside the cab, or thrown out of the
machine and crushed. You must wear a seat belt when ! WARNING
using the machine. Fasten the seat belt before starting If the seat belt does not 'lock' when you check if the
the engine. seat belt is operating correctly, do not drive the
2-2-1-9 machine. Get the seat belt repaired or replaced
immediately.
! WARNING 2-2-2-1
Release the seat belt only after switching off the
engine.
2-2-1-10
A C
B
S106842 S106842
S106842 S106842
8710-1

26
OPERATION 26
CAB LAYOUT
1 Steering Wheel 10 Forward/Reverse Lever (see Page 29)
2 Display Panel (see Page 35) 11 Gear Change Switch (see Page 28)
3 Steering Column Switch (see Page 30) 12 Heater Controls (see Page 39)
4 Engine Starter/Stop Switch (see Page 32) 13 Hazard Light Switch (see Page 31)
5 Steering Column Tilt Lock (see Page 33) 14 Loader Controls Lock (see Page 34)
6 Accelerator Pedal (see Page 27) 15 Loader Controls (see Page 40)
7 Parking Brake Switch (see Page 27) 16 Emergency Glazing Breaker (see Page 23)
8 Brake Pedal (see Page 27) 17 Parking Brake Lever (see Page 27)
9 Master Warning Light (see Page 37)
1
9
£ 4
!
3
0 2
^ 5
8
%
7
6
$
&
371930
8710-1

27
OPERATION 27
DRIVE CONTROLS, SWITCHES AND INSTRUMENTS
Controls
1 Accelerator Pedal 3c Parking Brake Transmission Disconnect
Push this pedal down to increase the engine speed. When fully engaged, the parking brake electrically
Let the pedal up to reduce the engine speed. With disconnects the transmission drive; this prevents the
your foot off the pedal, the engine will idle. machine from being driven with the parking brake on.
2 Brake Pedal ! CAUTION
The parking brake must not be used to slow the
Push down on the brake pedal to slow or stop the machine from travelling speed, except in an
machine. Use the brakes to prevent overspeeding emergency, otherwise the efficiency of the brake will
down a slope. be reduced. Whenever the parking brake has been
used in an emergency, always renew the brake pads.
3 Parking Brake 4-2-1-1-/1
3a 446 - Lever Operated
Use this lever to engage the parking brake before

leaving the machine. With the parking brake
engaged, an audible warning will sound, the master
warning light will illuminate and the “PARK BRAKE”
message will be displayed, when the forward/reverse
lever is moved away from neutral (N).
To engage the parking brake, pull the lever up as

shown. Check that the indicator light comes on.
To release the parking brake, lower the lever as far as

it will go. Check that the indicator light goes out.
3b 456 - Push Button Operated
Use this switch to engage the parking brake before

leaving the machine. With the parking brake
engaged, an audible warning will sound, the master
warning light will illuminate and the “PARK BRAKE”
message will be displayed, when the forward/reverse
lever is moved away from neutral (N).
To engage the parking brake, push the button. Check

that the indicator light comes on.
To release the parking brake, turn the button. Check

that the indicator light goes out.
Note: If the parking brake is not engaged when the

ignition is switched OFF, it will automatically be
engaged when the ignition is switched ON and will
remain engaged.
To release the parking brake, use the button to switch
on and then off again.
8710-1

28
OPERATION 28

(continued)
Controls (Continued)
4 Gear Change Switch 5 Transmission Kickdown
When the machine is stationary, make sure the Press the button B on the end of the lever or Top
forward/reverse lever and switch are in neutral button on loader lever to operate the transmission
position and the engine at idle speed before selecting kickdown.
a gear range.
The machine can be moved off in any gear range, With A/M Switch OFF
depending on ground conditions.
! CAUTION
To select a gear range, rotate the barrel A so that the With the A/M switch OFF, kickdown will be selected
arrow marked on the barrel aligns with the required regardless of road speed.
gear range. 0016
1st gear will remain selected. If another range or direction is

Selector (With A/M Switch OFF) selected or either of the kickdown buttons are pressed, the
M = Manual Mode. Allows the operator to manually select kickdown will be cancelled and 2nd gear will be selected.
and hold 1st, 2nd or 3rd gear.
Note: There is also a kickdown button on the loader control
Position Range lever.
1 Ist gear only

2 2nd gear with kickdown to 1st gear (If With A/M Switch ON
kickdown button is pressed again, reverts to
2nd gear) Kickdown Button Pressed ONCE
3 3rd gear only
4 2nd-3rd-4th-3rd-2nd with kickdown to 1st Shifts to next lowest gear (Dependant on road speed)
gear. and autoshifts up and down but only as high as the
gear selected after the button was pressed. If button
Note: Kickdown only operates with 2nd gear selected. is pressed again, reverts to autoshift.
Note: Reverse has only 3 gears (1st, 2nd and 3rd) Kickdown Button Pressed TWICE (double press)
Shifts to next lowest gear, (Dependant on road

Selector (With A/M Switch ON) speed) the system will shift though the gears in
A = Autoshift Mode. Autoshifts from 1st to the gear sequence to 1st gear if required. If button is pressed
selected on barrel A. ONCE, reverts to autoshift.
Position Range
1 Ist gear only.

2 Autoshift 1st-2nd-1st gear.
3 Autoshift 1st-2nd-3rd-2nd-1st gear.
4 Autoshift 1st-2nd-3rd-4th-3rd-2nd-1st gear.
Note: Reverse has only 3 gears (1st, 2nd and 3rd)
Note: For location of A/M Switch, see Switches in this

section.
A
Be
S187930A
8710-1

29
OPERATION 29

(continued)
Controls (Continued)
6 Forward/Reverse Lever
! CAUTION
! WARNING Do not operate the Forward/Reverse switch on the
You and others can be killed or injured if you operate loader control lever when already using the
the forward/reverse lever while travelling. The machine Forward/Reverse lever otherwise the transmission will
will immediately reverse direction without warning to select neutral. When using the Forward/Reverse
others. Follow the recommended procedure for proper switch, the Forward/Reverse lever MUST be locked in
use of this selector. neutral.
2-2-2-4 4-2-1-6
! WARNING
Reversing
Reversing at high speeds can cause accidents. Do not
reverse in a high gear with full throttle. Always drive at
a safe speed to suit working conditions.
INT-2-2-9/1
Stop the machine before moving this lever. To select

forward (F), reverse (R) or neutral (N), move the lever
to the position shown. The engine will only start if the
lever is in neutral (N).
To reverse direction:
a Stop the machine: keep the foot brake applied. F

b Let the engine speed drop to idle.
c Select the new direction.
d Release the foot brake and accelerate away.

N
If the parking brake is engaged when the
forward/reverse lever is moved away from neutral (N)
an audible warning will sound and the Parking Brake
Engaged Indicator will light. R
S187940A
Neutral Lock
To prevent accidental operation of the forward/reverse

lever, while entering or leaving the cab, the lever can be
locked in the neutral position.
With the selecter in the position marked N, the lever is

locked in neutral.
With the selecter in the position marked D, forward or N D

reverse drive may be selected.
S203710
8710-1

30
OPERATION 30

(continued)
Switches
Steering Column Switch Loader Control Lever Switches
1 Direction Indicators (Right) 7 Transmission Dump

Pull the lever towards you to indicate a right turn.
Switch the indicators off when you have completed Press the button to disconnect the transmission.
the turn. Functions only with the starter switch at
IGN. 8 Transmission Kickdown
2 Direction Indicators (Left) Press the button to operate the transmission

Push the lever away from you to indicate a left turn. kickdown.
Switch the indicators off when you have completed
the turn. Functions only with the starter switch at 9 Forward/Reverse
IGN.
Push switch to select Forward F. Pull switch to select
3 Windscreen Wiper Reverse R.
Rotate the lever barrel towards you to switch the When the switch is in the central position, Neutral N
windscreen wipers on. Rotate further to increase the is selected. See Forward/Reverse Switch.
speed of the wipers. Rotate the lever barrel away
from you to switch the intermittent wipe on.
Functions only with the starter switch at IGN. ! CAUTION
Do not operate the Forward/Reverse switch on the
4 Horn loader control lever when already using the
Press the button on the end of the lever to operate Forward/Reverse lever otherwise the transmission will
the horn. Functions only with the starter switch at select neutral. When using the Forward/Reverse
IGN. switch, the Forward/Reverse lever MUST be locked in
neutral.
5 Headlight/Mainbeam 4-2-1-6
Push the lever down for main beam. Centre position
is dipped beam. Functions only with the side/head
lights on.
6 Windscreen Washer
Push the collar around the horn button to operate the
windscreen washer. Functions only with the starter 8
switch at IGN.
7 Headlight Flash
Lift the lever for headlight flash. Functions only with
7
the starter switch at IGN. F
N
9
R
2
7
6
3
4
1
5
S268870 A351640
8710-1

31
OPERATION 31

(continued)
Switches (Continued)
Roof Panel Switches Roof Panel Switches (Continued)
Side Lights/Headlights Heated Seat

Press down for side lights only. Press further Press down to switch on heated seat
down for side lights and headlights. .
! WARNING Auto/Manual Transmission
A/M
Do not drive on the road with the work lights switched Press down to select automatic transmission
on. You can dazzle other drivers and cause an mode.
accident.
2-2-2-5
Front Work Lights Rotating Beacon
Press to switch on the front work lights. The Press down to switch on the rotating beacon.
light in the switch comes on with the work Note: The beacon should only be operated
lights. Functions with the starter switch at when in the vertical position.
IGN
Transmission Dump Inhibit Right Console Switches

Press switch to select transmission dump
(transmission disconnect) when brake pedal Automatic Carry Control System Inhibit
is pressed. (if fitted)
Press down to switch ON the automatic carry
! WARNING control system.
With the dump switch selected, there is no engine
braking when the brake pedal is pressed. When Air Conditioning (if fitted)
travelling on public roads, always deselect the dump Press down to switch on the air conditioning.
switch
4-2-1-5/1
Rear Fog Light (if fitted)
Press to switch on the rear fog light. The light Hydraulic Circuit Changeover (if fitted)
will come on only after dipped head lights are Press down to select 4th spool. The switch is
switched on. illuminated when the 4th spool is selected.
The 3rd spool is selected when the switch is
Rear Work Lights (if fitted) off.
Press to switch on the rear work lights. The
work lights will come on only after the side Cigar Lighter
lights are switched on. Push knob down until it latches. Do not hold
the knob in the depressed position. The
Rear Window Wash/Wipe knob will spring back to its stowed position
Press down to switch on the rear window when ready for use.
wiper. Press further down for window wash.
(The switch will spring back to the 'wipe' Note: The lighter must not be used for any other purpose
position when you release it.) than that for which it is intended.
Heated Rear Window Note: If the 24/12 volt converter is fitted, the lighter may
Press down to switch on the rear window be used as a 12 volt auxiliary power socket.
heater.
Steering Column Fairing Switch
Heated Mirrors Hazard Warning Lights

Press down to switch on the mirror heaters. Press down to switch on the hazard warning
lights. The light in the switch flashes with the
hazard warning lights.
8710-1

32
OPERATION 32

(continued)
Switches (Continued)
Starter Switch Forward/Reverse Switch
This is a rotary switch A, operated by the starter key. It This is a rocker switch mounted on the loader control
has four positions O - IGN - H - HS. The key can be lever, used to control the direction of the machine as an
removed only with the switch set to O. alternative to the Forward/Reverse Lever mounted on the
steering column.
O Return the key to this position to stop the
engine. Make sure the transmission is in neutral, To prevent accidental operation of the forward/reverse
the attachments have been lowered and the lever, the lever may be locked in the neutral position. See
parking brake is engaged before stopping the Neutral Lock.
engine.
! CAUTION
IGN Putting the switch to this position connects the Do not operate the Forward/Reverse switch on the
battery to all electrical circuits except the lights loader control lever when already using the
and hazard warning circuits. (The lights and Forward/Reverse lever otherwise the transmission will
select neutral. When using the Forward/Reverse
hazard warning circuits are permanently live).
switch, the Forward/Reverse lever MUST be locked in
The starter key will spring back to this position
neutral.
when it is released from positions H or HS 4-2-1-6
H Heat position. Holding the key in the heat Loader Control Lever Direction Control
position switches on a glow plug. The glow plug
warms the engine induction manifold for cold Note: The procedure for reversing direction is the same as
weather starting. Do not hold in this position for for the Forward/Reverse Lever.
more than 15 seconds.
Push switch to select Forward. Pull switch to select
HS Start position. Operates the starter motor to reverse. When the switch is in the central position N,
turn the engine. Neutral is selected.
Note: Do not operate the starter motor for more than 20 Note: Direction change may be controlled by either the
seconds at one time. Let the starter motor cool for at least Forward/Reverse Lever or the Forward/Reverse Switch on
two minutes between starts. the loader control lever.
7
F
N
A 9
R
S199400
A351640
8710-1

33
OPERATION 33

(continued)
Steering Wheel Tilt - Adjustment

1 Rotate lever A anti-clockwise to unlock the steering
column.
2 Adjust the steering column position. Re-tighten lever

to prevent the steering column from moving.
! CAUTION
Make sure the steering column is fully clamped before
driving the machine.
5-2-1-3
Note: The locked position of lever A can be altered - pull

the lever out and move to the required position.
S269670
Cab Interior Light

To switch light on, push up on end of light, to switch light
off, push up on other end of light.
The cab interior light does not need the starter switch to
be in the 'IGN' position before it will operate. Make sure
the light is turned off when you intend to leave the
machine for a long period of time.
S201940
8710-1

34
OPERATION 34

(continued)
Battery Isolator Switch

The battery isolator switch is located in the battery
compartment, under the left side top step.
Turn the isolator key C anti-clockwise to isolate the

machine electrical system from the batteries. When the
key is in the off position, it is not secure; it should be
removed. The key should be removed when the machine
is not in use, as a security precaution.
! CAUTION C
Except in an emergency, do not use the battery
isolator to switch OFF the engine. Failure to comply
may result in damage to the electrical system.
INT-3-2-13
S269740
LOADER CONTROL LOCK
To prevent the hydraulic controls from being operated

accidentally when the driver is entering or leaving the cab,
a safety locking lever A has been installed.
Controls locked (B) Lever down.
Controls Unlocked (C) Lever forward
The loader controls must always be locked before the

driver leaves the machine cab.
The loader controls must only be unlocked when the driver A

is correctly seated and there is no danger of accidentally
knocking against the hydraulic control levers.
C
S269660
8710-1

35
OPERATION 35
DISPLAY PANEL
Ignition On Setting up
During the first second after switching on, all LCD 1 Turn on the power by turning the starter key to IGN.
segments and warning lights are illuminated then the
software version is displayed on the top line. 2 Pressing the SETUP/SELECT button while in Pre-
Start Mode will allow the display to be set up as
Pre-Start Mode follows:
Note: Use the up and down arrows to adjust display as

required.
1. CLK FORMAT
The clock format (12/24 Hour) is shown in
50 the top right corner.
40 RPM
30 SETUP
2. HOUR
mph
20
20
30 SELECT 3. AM/PM
10 10
mph With 12 Hour selected, AM or PM is
MANUAL
0 0 selected and is displayed in the top left
corner.
4. MINUTE
5. YEAR
P
6. MONTH
7. DATE (Day)
8. LANGUAGE
A347010
English is the default language, there is one
The following are checked: alternative language. Certain languages are
not available.
Battery Voltage 9. Returns the display to Pre-Start Mode.
Illuminated if the battery voltage is low.
Hydraulic Fluid Temperature
Illuminated if the temperature is high.
Transmission Oil Temperature Start Inhibit
Illuminated if the temperature is high.
Coolant Temperature The following warnings will also cause the “START
Illuminated if the temperature is high. INHIBIT” message to be displayed. The engine will not
Fuel Level start until the fault is cleared.
Flashes when only 10% of fuel is left in the tank.
CAN-Bus Error
Illuminated if EMS receives a CAN bus error from the
ZF Computer.
The following warning lights will also illuminate and the If Neutral is not selected, the panel will display the
buzzer will sound: message “IN GEAR” and the buzzer will sound.
Alternator No Charge If the parking brake is on and the transmission is not in

neutral, the message “PARK BRAKE” will also be
Brake Pressure Low (Unless accumulators are still displayed.
charged)
Parking Brake On START INHIBIT can be overridden by pushing the
P MANUAL button once.
Engine Oil Pressure Low
Steering Pressure Low
8710-1

36
OPERATION 36
DISPLAY PANEL
(continued)
Warning Lights Visual Warning plus Buzzer and Message
The message associated with these warnings will be

Visual Warning Only displayed on the top line of the display panel.
Direction Indicators
Left or Right flashes with the direction Battery Voltage Low
indicators. Both flash when Hazard Warning Lights up when the battery voltage is low.
Lights are on. Use the indicators to signal “BATTERY LOW”
before turning.
No Charge
Hazard Warning Operates when the battery charging circuit
Flashes with the hazard warning lights (even fails while the engine is running. The light
with the starter switch at O). Switch the should go out a few seconds after the engine
flashers on whenever your machine is a is started. “ALTERNATOR”
possible hazard.
Engine Oil Pressure Low
Operates if the engine oil pressure drops too
Side Lights On far. The light should go out when the engine is
Lights up when the side lights are switched started. “ENG OIL PRESS”
on.
Brake System Pressure Low

Main Beam On Lights up when the brake system pressure is
Lights up when the headlight main beams are low. “BRAKE FAILURE”
switched on. Switch the main beams off for
on-coming vehicles. Main Steer System (If fitted)
Lights up if the main hydraulic system
pressure fails. Stop the machine as soon as it
Dip Beam On is safe to do so and rectify the fault.
Lights up when the headlight dipped lights are “STEERING PRESS”
switched on.
Hydraulic Fluid Temperature High

Front Work Lights On Operates if the hydraulic fluid temperature
Lights up when the front work lights are rises too high. “HYD OIL TEMP”
switched on.
Transmission Oil Temperature High

Rear Work Lights On Operates if the transmission oil temperature
Lights up when the rear work lights are rises too high. “TRANS OIL TEMP”
switched on.
Water Temperature High

Rear Fog Light On Operates if the engine coolant temperature
Lights up when the rear fog light is switched rises too high. “COOLANT TEMP”
on.
Emergency Steer Pump (If fitted) Air Filter Blocked

Lights up when the emergency steering Operates if the engine air filter clogs up.
system is operating. ie. When the machine is “AIR FLTER BLKD”
moving.
Parking Brake Engaged

P Lights up when the parking brake is engaged.
8710-1

37
OPERATION 37
DISPLAY PANEL
(continued)
Visual Warning and Message Segmented Displays

The message associated with this warning will be 5 0 Speedometer
4 0
displayed on the top line of the display panel. 3 0 Indicates the road speed. The road speed
k p h
2 0 3 0 is shown on the right side in miles per

2 0
m p h
hour (mph) and kilometres (kph) on the left
Service Required 1 0 1 0
side.
If lit, contact your JCB Distributor. 0 0
“SERVICE REQD” Fuel Gauge

Indicates the level of fuel in the tank. See
Note: The “SERVICE REQD” message is displayed in Pre- Types of Fuel in MAINTENANCE section
Start mode only. for fuel to be used. Do not let the tank run
dry, or air will enter the fuel system.
Note: If diagnostic option is fitted, the Service Required
warning and message will be displayed at pre-set intervals Note: The message “LOW FUEL” is displayed on the panel
and also if the diagnostic computer memory is full. The when only 10% of fuel is left in the tank.
Service Required is reset when data is down loaded by
your JCB distributor.
Water Temperature Gauge
Indicates the working temperature of the
Automatic Engine Shut Down engine coolant. Do not let the indicator
rise to the red danger zone of the gauge.
The following warnings will also initiate the automatic
engine shut down system.
Transmission Oil Temperature
transmission oil. Do not let the indicator
rise to the red danger zone of the gauge.
A 30 second count down to engine shut down starts as
soon as the warning symbol is illuminated.
Hydraulic Fluid Temperature
The count down time is displayed on the top line of the
display alternating with the appropriate warning dialogue.
hydraulic fluid. Do not let the indicator rise
to the red danger zone of the gauge.
In an emergency, the MANUAL button will reset the
counter to 30 seconds; this will allow the machine to be
moved if necessary.
Although there is no limit to the number of times the

button may be pressed, each press of the MANUAL Master Warning Light
button is remembered in the diagnostic data logger.
The master warning light will illuminate to draw attention
Note: The ignition must be switched OFF after a shut
to the display panel if any of the visual warnings operate.
down to enable the system to reset.
Transmission Fault
In the event of the transmission developing a fault, the

EMS will display a fault code to aid diagnosis.
The fault code will be displayed on the top line of the

display panel. An example of a fault code is shown below.
ZFCB ERROR ??
A list of the fault codes is given in the Service Manual

(9803/4160 Section F).
8710-1

38
OPERATION 38
DISPLAY PANEL
(continued)
Indications (Engine Off)
Indicates that machine hours are displayed top

left of the display.
50
40 RPM
mph
30 SETUP Indicates that time is displayed top right of the
20
20
30 SELECT display.
10 mph
10
MANUAL
0 0
! CAUTION
All the warning lights should go out when the engine is
started. Rectify any faults immediately.
4-2-1-4
P
A347010
Indications (Engine Running) Indicates that transmission information is

displayed top left of the display.
Indicates that time is displayed top right of the

display.
50
40 RPM
30 SETUP
mph
20 30 SELECT
20
10 mph
10
MANUAL
0 0
The gear in use is indicated top left of the display.
Note: Neutral (N) is displayed until the parking brake is

disengaged when ranges 1 or 2 are selected.
P
A347020
Warning Light Test (Daily)
1 Turn on the power by turning the starter key to IGN.
2 All the fault warning lights should illuminate during

the start up cycle.
3 If any of the fault warning lights fail to illuminate,

contact your JCB Distributor.
! CAUTION
Do not use the machine if any of the warning lights do
not illuminate. Have the fault rectified immediately.
4-2-1-3
8710-1

39
OPERATION 39
HEATER/AIR CONDITIONING CONTROLS
1 Air Recirculation 2 Temperature

Turn to the left to recirculate air in the cab. Turn to Turn to the right to increase the heat.
the right for fresh air from outside.
3 Fan
The control can be adjusted to give a combination of Turn to switch on the cab three-speed heater fan.
recirculated and fresh air. Turn further for faster speeds. It functions only with
the starter switch on.
Note: In dusty conditions, it is recommended that air be
recirculated within the cab, otherwise the filter may
become clogged. Four air vents B are located on the cab pillars, a further
three air vents C are located on the console and one air
vent D is located low down on the side console. The vents
can be turned to direct the air flow where required. When
the vents are open, hot or cold air will flow directly into the
cab.
For the most effective front window demisting, the air

vents should be closed and air circulation control turned
fully to the left.
B
B C
C
B
D
1
3
2
372300
8710-1

40
OPERATION 40
LOADER CONTROLS
Standard Shovel
1 Loader arm raise.
2 Loader arm lower.
3 Arm float
Push the lever forward as far as it will go, and leave it
there.
4 Shovel open.
5 Shovel close.
! CAUTION
If Float is selected with the loader raised, the loader
will descend to ground level and 'float' across it as you
travel. You will have no control over the rate of fall.
2-2-2-7
3
2
4
5
A351650
1
5
4
2
3
A262830
8710-1

41
OPERATION 41
LOADER CONTROLS
(456HT)
Adjusting the Loader Arm Preset Height Adjusting the Shovel Preset Angle
To adjust the preset height, raise the loader arm to the To adjust the shovel preset angle, set the shovel to the
height required and adjust the position of the proximity angle required, with the shovel on the ground.
switch A in line with loader arm B, by loosening nuts C
and D. Tighten nut C first to set the proximity switch Switch off the Engine.
position then tighten nut D.
Adjust bar D, so that the end of the bar is in line with the
Test the loader arm automatic kickout for correct proximity switch E, by loosening locknuts F. Secure
operation and adjust if necessary. locknuts F after adjustment.
Note: The detent position is only selectable when the Test the shovel automatic reset for correct operation and
proximity switch is out of range of the sensor bar. adjust if necessary.
Note: The detent position is only selectable when the

Testing the Loader Arm Preset Height proximity switch is out of range of the sensor bar.
Pull the loader control lever back (to raise the loader arm);
release the lever as soon as the loader arm starts to rise. Testing the Shovel Preset Angle
The loader arm should stop at the preset height. Raise the loader arms enough for the shovel to clear the
ground when dumped.
Move the loader control lever to the right (to fully dump the
shovel).
Move the loader control lever to the left (to close the
shovel); release the lever as soon as the shovel starts to
move.
The shovel should stop at the preset angle.
B
A D
E
D
F
F
297620 S201750
8710-2

42
OPERATION 42
LOADER CONTROLS
(446 & 456ZX)
Adjusting the Loader Arm Preset Height Adjusting the Shovel Preset Angle
To adjust the preset height, raise the loader arm to the To adjust the shovel preset angle, set the shovel to the
height required and adjust the position of the proximity angle required, with the shovel on the ground.
switch A in line with loader arm B, by loosening nuts C
and D. Tighten nut C first to set the proximity switch Switch off the Engine.
position then tighten nut D.
Adjust bar D, so that the end of the bar is in line with the
Test the loader arm automatic kickout for correct proximity switch E, by loosening bolts F. Secure bolts F
operation and adjust if necessary. after adjustment.
Note: The detent position is only selectable when the Test the shovel automatic reset for correct operation and
proximity switch is out of range of the sensor bar. adjust if necessary.
Note: The detent position is only selectable when the

Testing the Loader Arm Preset Height proximity switch is out of range of the sensor bar.
Pull the loader control lever back (to raise the loader arm);
release the lever as soon as the loader arm starts to rise. Testing the Shovel Preset Angle
The loader arm should stop at the preset height. Raise the loader arms enough for the shovel to clear the
ground when dumped.
Move the loader control lever to the right (to fully dump the
shovel).
Move the loader control lever to the left (to close the
shovel); release the lever as soon as the shovel starts to
move.
The shovel should stop at the preset angle.
B
A
F D
D F
E
C
297620 S264480
8710-2

43
OPERATION 43
BEFORE STARTING THE ENGINE
Note: Read Operating in Low Temperatures or ! WARNING

Operating in High Temperatures in OPERATION section,
Loose articles can fall and strike you or roll on the
if you will be using the machine in very cold or very hot
floor. You could be knocked unconscious, or the
climates.
controls could get jammed. If that happens you will
lose control of the machine.
1 The parking brake should have been engaged when 2-2-3-7/1
the machine was last parked. But if it is not already
engaged, engage it now. e Remove or secure all loose articles in the cab -
such as lunch boxes, tools etc.
! DANGER
f Inspect the ROPS/FOPS structure for damage. Get
Before lowering the attachments to the ground, make
your JCB distributor to repair any damage. Make
sure that the machine and the area around it are clear
sure all its securing bolts are fitted and correctly
of other people. Anyone on or close to the machine
tightened.
could fall and be crushed by the attachments, or get
caught in the linkages.
2-2-3-4
g Check round the cab for loose or missing bolts,
screws etc. Replace or tighten where necessary.
2 Lower the Loader Shovel to the ground, if it is not
already there. It will lower itself under its own weight ! WARNING
when you operate the lever. Operate the lever A JCB approved seat belt is fitted to your machine.
carefully to control the rate of descent. Replace it with a new one if it is damaged, if the fabric
is worn, or if the machine has been in an accident. Fit a
! WARNING new seat belt every three years regardless of
On machines fitted with hose burst protection valves condition.
2-3-1-8/1
the attachments cannot be lowered with the engine
stopped. On these machines start the engine and
h Inspect the seat belt and its mountings for damage
lower the attachments before doing the walkround
and excessive wear.
inspection.
2-2-3-5
! WARNING
3 For your own safety (and others') and for a maximum Do not use a seat belt which is damaged or
service life of your machine, do a pre-start inspection excessively worn.
before starting the engine.
Do not use a seat belt that has been in an accident.
a If you haven't already done it, do a walkround
inspection of the outside of the machine. A worn, damaged or already stressed seat belt could
break or give way in a collision. If that happens you
b Remove dirt and rubbish from the cab interior, could be killed or injured.
specially around the pedals and control levers. 2-2-3-8
! WARNING ! WARNING
Keep the machine controls clean and dry. Your hands o not drive the machine without wearing the seat belt,
and feet could slide off slippery controls. If that properly fastened and adjusted.
2-2-3-9
happens you will lose control of the machine.
2-2-3-6
i Check that the following are in working order:
c Remove oil, grease and mud from the pedals, Lights, Warning Lights, Rotating Beacon, Horn,
control levers and the steering wheel. Indicator Lights, All Switches, Direction Indicators,
Hazard Warning Lights, Windscreen Washer and
d Make sure that your hands and shoes are clean Wipers.
and dry.
8710-2

44
OPERATION 44
BEFORE STARTING THE ENGINE

(continued)
4 Adjust the seat so that you can comfortably reach all

the driving controls. You should be able to apply full
brake pedal travel with your back against the seat
back.
5 Adjust the steering column so that you can reach the

steering wheel and the steering column switches 8
without stretching.
5
6 Set the rear view mirror(s) to give you a good view
close behind the machine when you are correctly
seated.
7 Fasten and Adjust the Seat Belt.
8 The engine will not start unless the forward/reverse

lever and the forward/reverse switch on the loader
lever are in neutral (N).
A351700
8710-2

45
OPERATION 45
STARTING THE ENGINE
! WARNING Note: New engines DO NOT require a running-in period.

The engine/machine should be used in a normal work
Seat Belt
cycle immediately; glazing of the piston cylinder bores
Operating the machine without a seat belt can be
resulting in excessive oil consumption, could occur if the
dangerous. Before starting the engine, make sure your
engine is gently run-in. Under no circumstances should the
seat belt is fastened. Check the tightness and
engine be allowed to idle for extended periods; (e.g.
condition of the seat belt anchorage bolts regularly
warming up without load).
(see maintenance schedules).
INT-2-1-8/1
1 Read and comply with Before Starting the Engine

(OPERATION section).
Note: If the outside temperature is low, say 0 °C (32 °F) or

below, turn the starter switch key to H for 10-15 seconds
to warm the engine induction manifold.
! WARNING
Cold Starting
Do not use ether or other starting fluids to assist cold A
starting. Using these fluids may result in an explosion IGN
causing possible injury and/or damage to the engine.
H
3-2-1-9
HS
2 a Fully depress accelerator pedal B.
b Turn starter key A fully clockwise to HS to start the

engine. 385460
Note: If the engine has not started after 20 seconds,

release the starter switch. Wait two minutes before
attempting another start. This will allow the starter motor
to cool down.
A
c Release the starter key as soon as the engine
starts. The switch will return to IGN.
d Ease off on the accelerator pedal to reduce engine

speed.
B
3 Check the Warning Lights
Once the engine has started, check that all the

warning lights have gone off. Do not race the engine
until the oil pressure low light has gone out. Check
that the audible alarm is silent.
Note: 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. A351710
8710-2

46
OPERATION 46
JUMP-STARTING THE ENGINE
! WARNING
Do not use a battery if its electrolyte is frozen. To
prevent the battery electrolyte from freezing, keep the
battery fully charged.
Do not 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

starter switch.
Do not connect the booster (slave) supply directly

across the starter motor. Doing this by-passes the
neutral gear safety switch. If the machine is in gear, it
may 'runaway' and kill or injure bystanders.
Use only sound jump leads with securely attached

connectors. Connect one jump lead at a time.
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.
This machine has a 24 volt, negative earth electrical

system. The booster (slave) supply must not be higher
than 24 volts. Using a higher voltage supply will
damage your machine's electrical system.
If you do not know the voltage of your booster (slave)

supply, then contact your JCB dealer for advice. Do
not attempt to jump-start the engine until you are sure
of the voltage of the booster (slave) supply.
4-2-2-2
8710-2

47
OPERATION 47
JUMP-STARTING THE ENGINE

(continued)
1 The parking brake should have been engaged when ! WARNING

the machine was last parked. If it is not engaged,
When the engine is running, there are rotating parts in
engage it now.
the engine compartment. Before disconnecting the
cables make sure that you have no loose clothing
! DANGER (cuffs, ties etc) which could get caught in rotating parts.
2-2-4-3
Before lowering the attachments to the ground, make
sure the machine and the area around it are clear of
7 a Disconnect the negative booster cable from the
people. Anyone on or close to the machine could fall
machine frame earth. Then disconnect it from the
and be crushed by the attachments, or get caught in
booster supply.
the linkages.
2-2-3-4
b Disconnect the positive booster cable from the
positive (+) terminal on the battery. Then
2 Lower the loader shovel to the ground, if it is not disconnect it from the booster supply.
already there. It will lower itself under its own weight
when you operate the lever. Operate the lever 8 Close the left side top step and the tool stowage box.
carefully to control the rate of descent. If your
machine is fitted with hose burst protection valves
you will not be able to lower the shovel. In this case
install the safety strut, or block the shovel to prevent
any chance of it falling.
3 Set all switches in the cab to off.
4 Connect the booster cables as follows:
a To gain access to the battery, close the cab door,

open the tool stowage box A. Unlock the battery
bay door (left side top step) by pulling knob B. A
! 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
metalwork. If this happens you can get burned.
B
Make sure that the fuel filler cap is tightly fitted. Make
sure that all spilt fuel is cleaned away from the battery
area.
2-2-4-2
397150
b 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.
c Connect the negative (-) booster cable to a good
frame earth on the machine, away from and below
the battery.
Note: A good frame earth is part of the main frame, free
from paint and dirt. Do not use a pivot pin for an earth.
d Connect the other end of this cable to the negative

(-) terminal on the booster supply.
5 Do the pre-start checks.
6 Start the engine.

S269740
8710-2

48
OPERATION 48
TRAVELLING POSITION
On Site On Public Roads
! WARNING ! WARNING
A high loader shovel can block your view and reduce Do not drive on the road with the work lights switched
the stability of the machine. Travel with the loader low on. You can dazzle other drivers and cause an
to the ground. Travel slowly and with caution over accident.
rough, muddy or loose surfaces. 2-2-2-5
2-1-1-3
1 Make sure the tooth guard is fitted on the shovel.
1 Lower/raise the shovel to approximately 300 mm (12
in) above the ground. Note: In certain territories you will be breaking the law if
you do not fit a tooth guard to the shovel. Make sure you
2 Pull lever A to the left and fully 'close' the shovel as are complying with local laws.
at X.
2 Lower/raise the shovel to approximately 300 mm (12
Note: Keep the shovel 300 mm (12 in) above the ground in) above the ground.
when:
3 Pull lever A to the left and fully 'close' the shovel as
a Travelling with a full shovel. at X.
b Reversing up a gradient.
c Travelling across a gradient. 4 Switch on the flashing beacon.
In the U.K., before travelling on public roads, it is your

responsibility as a user to comply with The Road Vehicles
Construction and Use)(Amendment) Regulations 1997
(“Bridge Bashing Regs.”). By way of guidance only, the
following steps may be taken to comply:
A Always assess your route for overhead structures such
as bridges which could be damaged by your machine.
Utilise the restraint device, see Height Restriction

System in this section, to ensure that the equipment is
in the travelling position.
IMPORTANT NOTICE: Whilst this information is believed

to be correct, JCB cannot be aware of all circumstances in
which JCB machines may be operated on a Public
A351670 Highway and it is the responsibility of the user to ensure
compliance with the regulations.
Automatic Carry Control System - ACCS (If fitted)
When travelling over rough ground at speed, the ACCS

system will reduce machine bouncing and pitching.
The system operates above 7 kph (4.4 mph) road speed.

When the system starts to operate, the loader arms may
lift slightly; the amount will depend on the load being
carried. X
! CAUTION
ACCS must be switch OFF when travelling on the road
with the Height Restriction System engaged.
4-2-3-3
A351580
8710-2

49
OPERATION 49
GETTING THE MACHINE MOVING
After you have warmed up the engine, move off as 1 Make sure that your seat belt is correctly fastened
described below. Read the Operating Hints and and adjusted. Make sure that the seat is correctly
WARNING first. adjusted.
Operating Hints 2 Select a gear (range) to suit the conditions and the
job you will be doing.
When moving the machine, keep it under control at all
times. Stay alert for obstructions and possible hazards. Note: Now that you have engaged a gear, the road wheels
will be connected to the engine as soon as you move the
! WARNING forward/reverse lever or switch away from neutral (N).
Do not dismount a moving machine.
3-2-3-12 Depending on the ground condition and the gear you have
selected, the machine may then try to move off before you
Do not use the brake pedal as a footrest. are ready. The following procedure makes sure you keep
full control of the machine.
Do not coast the machine in neutral, you will not have full
control. Also, coasting the machine will cause damage to 3 a Check that the attachments are in one of their
the transmission. travel positions. Push the brake pedal hard down.
Release the parking brake. Select forward (F) or
Select the necessary gear before starting down a slope. reverse (R).
Use the same gear you would use to go up the slope. Do
not change gear on the slope. Note: When forward (F) or reverse (R) drive is selected, an
audible alarm will sound and a warning light will show to
If the load will be pushing the machine on a downslope, remind you that the parking brake is still engaged. Make
select the first gear (1) before starting downhill. sure the procedure for moving the machine is followed in
the sequence given in this section.
Use the brake pedal to prevent overspeeding down a
slope. (Deselect transmission dump) b Make sure it is safe to move off, then release the
brake pedal and push down on the accelerator
Approach deep mud in first gear (1) with the front wheels pedal. The machine will move smoothly away.
straight.
c While the machine is travelling slowly, check the
Always stop the machine and drop engine speed to idle
steering and brakes. Do not drive the machine
before changing from forward to reverse or vice versa.
unless the steering and brakes are working
correctly. If you are not sure, assume they are
! WARNING faulty.
You and others could be killed or injured if you operate
the forward/reverse lever while travelling. The machine ! WARNING
will immediately reverse direction without warning to Rollover
others. Follow the recommended procedure for proper Should the machine start to roll over, you can be
use of this selector. crushed if you try to leave the cab. If the machine
2-2-2-4
starts to roll over, DO NOT TRY TO JUMP FROM THE
CAB, STAY IN THE CAB, WITH YOUR SEAT BELT
FASTENED.
INT-2-1-12
! WARNING
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.
INT-2-1-5
8710-2

50
OPERATION 50
STOPPING AND PARKING THE MACHINE
Where possible, stop the machine on dry and level 4 Operate the control levers to lower the
ground. shovel/attachments to the ground. Once they are on
the ground, operate the controls a little further so that
! WARNING they begin to take the weight of the machine.
Parking
Note: Make sure that the shovel/attachments lie flat on the
An incorrectly parked machine can move without an
ground to prevent accidental movement.
operator. Follow the instructions in this handbook to
park the machine correctly.
INT-2-2-4 Note: On turbocharged engines; before stopping the
engine, run at idling speed and reduced load for 2-3
1 Ease up on the accelerator pedal and down on the minutes to allow the turbocharger to cool down.
brake pedal to bring the machine to a smooth stop.
Keep the foot brake on until the parking brake has 5 Turn the starter key to the O position.
been engaged and the drive disengaged. (Steps 2
and 3). 6 If you are going to leave the machine, remove the
starter key.
2 Engage the parking brake. Make sure that the parking
brake indicator lights up. Release the foot brake. 7 If you are leaving the machine, make sure that all
unnecessary switches are switched off. If necessary,
Note: An audible alarm will sound and a warning light will leave the hazard warning and/or side lights switched
show when the parking brake is engaged with the machine on.
in forward (F) or reverse (R) drive. The alarm will stop
when neutral (N) drive is selected (step 3). ! CAUTION
Always face the machine when entering (and leaving)
3 Set the forward/reverse lever or switch to neutral. the cab. Make sure your hands and shoes are clean
Make sure the neutral lock is engaged. and dry. Otherwise you could slip and fall.
2-2-1-3
! DANGER
8 Use the handholds and step when you climb down
Before lowering the attachments to the ground, make from the machine. If you are leaving the machine,
sure that the machine and the area around it are clear close and latch all windows and lock the door.
of other people. Anyone on or near the machine could
fall and be crushed by the attachments, or get caught
in the linkages.
2-2-3-4
F
5
N
R
4
A351720 397710
8710-2

51
OPERATION 51
TESTING THE PARKING BRAKE
! WARNING 9 Press SETUP key again to select park brake test off.
Before testing the parking brake make sure the area
10 Lower attachment and stop the engine.
around the machine is clear of people.
2-2-4-5
Note: If the machine moved during the test, have your
Test the brake on a level, dry surface. Make sure your seat JCB distributor inspect the brake. Do not use the machine
belt is securely fastened. with faulty brakes.
1 The attachment should be in the travelling position. If you have any queries concerning this test procedure
or parking brake adjustment, consult your local JCB
2 Make sure the parking brake is fully engaged dealer.
3 Switch off transmission dump. ! WARNING

Do not use a machine with a faulty parking brake.
4 Switch off Auto/Manual switch. 3-2-3-10
5 Select third gear/range (barrel position 3) but remain ! CAUTION

in neutral. Non approved modifications to axle ratios, machine
weight or wheel and tyre sizes may adversely affect
6 a On the EMS press the two arrow keys and the the performance of the parking brake.
SETUP key at the same time, to select the AEB 3-2-3-11
setup menu.
b Use the UP or DOWN arrows to select the park

brake test menu.
c Press SETUP key to select park brake test on.
7 Push down hard on the brake pedal and select

forward drive.
Note: An audible alarm will sound and a warning light will

show when the parking brake is engaged with the machine
in forward (F) drive. The alarm will stop when neutral (N) is
selected.
! WARNING
If the machine starts to move during the following test,
immediately apply the foot brakes and reduce the
engine speed.
2-2-5-1
8 a Release the brake pedal.
b If the machine has not moved, use the accelerator

pedal to gradually increase the engine speed to
1500rpm. The machine should not move.
c Reduce the engine speed to idle and set the

forward/reverse lever (or switch) to neutral.
Do not do this test for longer than 20 seconds. Ensure

transmission temperature gauge does not enter the red
zone.
8710-2

52
OPERATION 52
USING THE ATTACHMENTS AND SITE SAFETY
This section explains some techniques for efficient and ! WARNING

safe use of the machine and its attachments. Attention is
Electrical Power Cables
also drawn to the various safety aspects of operating on
You could be electrocuted or badly burned if you get
site. Read and understand this section before you start
the machine or its attachments too close to electrical
working with the machine. Practice using the attachments
power cables.
until you are completely familiar with the controls and
what they do.
You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and
Before you start using the machine, tell your work mates
regulations concerning work near electric power lines.
what you will be doing and where you will be working. On
a busy site, use a signalman.
Buried Electric Power Cables
Before you start using the machine, check with your
Remember that your machine is mobile. Whenever
electricity supplier if there are any buried power cables
possible, manoeuvre your machine into a position which
on the site.
combines safety with efficiency. If you have to choose,
remember that:
Overhead Electric Power Cables
There is a minimum clearance required for working
SAFETY MUST COME FIRST beneath overhead power cables. You must obtain
details from your local electricity supplier.
Choose the correct attachment for the job. Do not use an 2-2-5-4
oversize shovel for rocky material. It could overload the
system and shorten service life.
! WARNING
! WARNING Reworking Old Sites
Work Sites There could be dangerous materials such as asbestos,
Work sites can be hazardous. Inspect the site before poisonous chemicals or other harmful substances
working on it. Look for potholes, weak ground, hidden buried on the site. If you uncover any containers or
rocks etc. Check for utilities such as electric cables you see any signs of toxic waste, stop the machine
(overhead and underground), gas and water pipes etc. and advise the site manager immediately.
2-2-5-5
Mark the positions of the underground cables and
pipes. Make sure that you have enough clearance
beneath overhead cables and structures. ! WARNING
INT-2-2-1
Water Supplies and Drains
Before you start using the machine, check with your
! WARNING local public water supplier if there are buried pipes and
drains on the site. If there are, obtain a map of their
General Site Safety
locations and follow the advice given by the water
Before you start using the machine, inspect the job
supplier.
site. You could be killed or injured if the ground gives
way under your machine or if piled material collapses
onto it. Check for potholes and hidden debris, logs,
ironwork etc. Any of these could cause you to lose
regulations concerning work near buried water pipes
control of your machine.
and drains.
2-2-5-2
2-2-5-6
! CAUTION ! WARNING
Legal Liability
Communications
You and/or your company could be legally liable for
Bad communications can cause accidents. Keep
any damage you may cause to public utilities. It is
people around you informed of what you will be doing.
your responsibility to make sure that you know the
If you will be working with other people, make sure any
locations of all public utility cables or pipes on the site
hand signals that may be used are understood by
which could be damaged by your machine.
everybody. Work sites can be noisy, do not rely on
2-2-5-3
spoken commands.
INT-2-2-3
8710-2

53
OPERATION 53
USING THE ATTACHMENTS AND SITE SAFETY

(continued)
! WARNING ! WARNING
Underground Gas Pipes Banks and Trenches
Before you start using the machine, check with your Banked material and trenches can collapse. Do not
local gas company if there are any buried gas pipes on work or drive too close to banks and trenches where
the site. there is danger of collapse.
INT-2-2-5
If there are buried gas pipes we recommend that you
ask the gas company for any specific advice regarding
the way you should work on the site. ! WARNING
Safety Barriers
Some modern gas pipes cannot be detected by metal Unguarded machines in public places can be
detectors, so it is essential that an accurate map of dangerous. In public places, or where your visibility is
buried gas pipes is obtained before any excavation reduced, place barriers around the work area to keep
work commences. people away.
INT-2-2-8
Hand dig trial holes to obtain precise pipe locations.
Any cast iron pipes found should be assumed to be
gas pipes until contrary evidence is obtained. ! WARNING
When transporting a load on a slope, drive slowly and
Older gas pipes can be damaged by heavy vehicles keep the load uphill of the machine. This will increase
driving over the ground above them. stability.
2-1-1-5
LEAKING GAS IS HIGHLY EXPLOSIVE.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on the
site. Ban smoking, ensure that all naked lights are
extinguished and switch off any engines which may be
running.

regulations concerning work near buried gas pipes.
2-2-6-1/1
! WARNING
Hillsides
Operating 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. Operate in first gear on hillsides, when
applicable keep all attachments close to the ground.
Never coast down a hill with the engine off or the
transmission in neutral.
INT-2-2-7
8710-2

54
OPERATION 54
OPERATING IN LOW TEMPERATURES
In low temperature situations, take the following Transmission Cold Start Procedure
precautions. They will make for easier starting and
prevent possible damage to your machine. At temperatures below -12ºC (10.4ºF), the ZF Computer
inhibits gear selection until the transmission has been
1 Use the correct viscosity engine lubricating oil. warmed up.
2 Use a low temperature diesel fuel (If available). If the EMS displays “ **”:
3 Use the correct coolant mixture.

Start the engine and warm up the transmission in neutral.
When the correct temperature is reached, the EMS will
4 Keep the battery at full charge.
display N.
5 Fill the fuel tank at the end of each work period.
6 Park the machine inside a building or cover it with a

tarpaulin.
! WARNING
Cold Starting
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.
3-2-1-9
7 In very low temperatures, eg -18 °C (0 °F) and below,

additional starting aids may be needed. Examples
are fuel, oil and coolant heaters and extra batteries.
Ask your JCB distributor for advice.
8 Remove snow from the engine canopy before

starting, otherwise snow could get into the air
cleaner.
OPERATING IN HIGH TEMPERATURES
In high temperature situations, take the following 4 Regularly remove dirt and debris from the radiator
precautions to prevent possible damage to the machine. and the engine.
1 Use the correct viscosity engine lubricating oil. 5 Check the fan belt regularly.
2 Use the correct coolant mixture. 6 Check the engine air filter regularly.
3 Keep the coolant at the correct level. Make sure

there are no leaks.
8710-2

55
OPERATION 55
MOVING A DISABLED MACHINE
Do not tow a machine unless there is no alternative. Preparation for Towing

Remember that further damage might be caused to the
machine by towing it. If at all possible repair the machine 1 Engage the parking brake.
where it stands. If the machine must be towed, read the
following CAUTION and use the procedure given here. 2 Select Neutral (N)
! CAUTION 3 a If the engine and hydraulic systems are not

Towing a machine too far or too fast can damage the damaged, raise the Loader Shovel to 900 mm (3 ft)
transmission. Do not tow the machine further than 10 above the ground, and fully 'close' the shovel.
km (6 miles). Use a trailer for greater distances. When This allows a straight pull from the attachment
towing do not travel faster that 10 kph (6 mph). point.
Use a rigid draw-bar. If you must use towing chains, b If the engine cannot be run, the Loader Shovel
then use two towing vehicles. One vehicle should be must be hoisted into position as described above
coupled to the front of disabled machine. The other and secured.
towing vehicle should be coupled to the rear of
disabled machine, to provide braking power. The procedure for doing this will depend on the
machine's condition and its hydraulic circuits.
The towing vehicle(s) must have enough pulling and
braking power to move and stop the machine. For this reason you should contact your JCB
4-2-5-4 distributor for help and advice before attempting this
work.
! WARNING
Block the loader arms before attaching the tow bar. 4 Attach the drawbar (or chain) to the front chassis side
4-2-5-2 plate hole (left or right).
5 Attach the chain to the recovery hitch. (If using

chains).
The machine is now ready for towing. Make sure you

understand what the towing driver will be doing. Obey his
instructions and all relevant regulations.
8710-2

56
OPERATION 56
TRANSPORTING THE MACHINE
The safe transit of the load is the responsibility of the c Carefully drive the machine onto the trailer.
transport contractor and driver. Any machine
attachments or parts that may move during transit d When the machine is safely in position, lower the
must be adequately secured Loader Shovel.
5-2-5-9
e Set the drive to neutral and engage the parking
Note: Before transporting the machine make sure you will brake.
be obeying the rules and laws of all the areas that the
machine will be carried through. f Check that the overall height of the load is within
regulations. Adjust if necessary.
Make sure that the transporting vehicle is suitable. See
Static Dimensions in SPECIFICATIONS section for the g Switch off the engine.
dimensions of your machine.
h Install the articulation lock.
! WARNING
Ramps and Trailers i Secure the cab.
Water, mud, ice, grease and oil on ramps or trailers
can cause serious accidents. Make sure ramps and j Cover the exhaust stack.
trailers are clean before driving onto them. Use
extreme caution when driving onto ramps and trailers. 3 Put blocks at the front and rear of all four tyres.
INT-2-2-6 Anchor the machine to the trailer with chains, using
the four holes A in the chassis side plates at the front
1 Place blocks at the front and rear of the trailer and rear.
wheels.
4 Measure the maximum height of the machine from
2 a Make sure the ramps are correctly in place and the ground. Make sure the truck driver knows the
secure. clearance height before he drives away.
b Raise the shovel to approximately 305 mm (12 in)
from the ground.
A
A
397160
8710-2

57
OPERATION 57
LIFTING THE MACHINE
Carry out the following procedure when lifting a machine: Take the weight of the machine. If the lifting equipment is
fouling on the machine use spreader bars to prevent
Lower the loader arms to the ground. damage.
Remove all attachments. Check that the lifting eye is positioned directly above the
machine centre of gravity, see Static Dimensions
Fit the articulation lock, see Installing the Articulation (SPECIFICATIONS section).
Lock (MAINTENANCE section).
! DANGER
Switch OFF the engine, remove the key, vacate the
machine and shut the door(s). Do not stand underneath a raised load. Stand clear
and to one side until the load has been safely lowered.
Remove all loose equipment from machine exterior. Make sure that the area is clear of other people before
lowering the load. If you do not follow these
Check the unladen weight of the machine, see Static precautions you or others could be killed or seriously
Dimensions (SPECIFICATIONS section). injured.
2-3-5-3
! WARNING ! WARNING
You can be injured if you use faulty lifting equipment.
Bad communications can cause accidents. Keep
Make sure that lifting equipment is in good condition.
people around you informed of what you will be doing.
Make sure that lifting tackle complies with all local
If you will be working with other people, make sure any
regulations and is suitable for the job. Make sure that
hand signals that may be used are understood by
lifting equipment is strong enough for the job.
everybody. Work sites can be noisy, do not rely on
INT-1-3-7
spoken commands.
INT-2-2-3
Attach lifting equipment to four lifting points A.
A
A
397160
8710-2

58
OPERATION 58
FIRE EXTINGUISHER
The fire extinguisher should be inspected daily.
! WARNING
Do not use the fire extinguisher in a confined space.
Make sure that the area is well ventilated during and
after using the extinguisher. A
4-2-3-1
B
Using the Fire Extinguisher
1 Remove extinguisher from its stowage bracket.
2 Remove safety pin B.
3 Aim directly at the fire, from an upwind position if

possible.
4 Squeeze trigger A to operate the extinguisher,

release the trigger to stop the flow.
! WARNING
After any use, the extinguisher should be replaced or
serviced.
S170520
4-2-3-2
RECOVERY HITCH
The recovery hitch C (if fitted) is rated at 100KN (22480lbf).
Note: The recovery hitch is not designed for towing and

MUST NOT be used as a tow hitch.
397170
8710-2

59
OPERATION 59
HEIGHT RESTRICTION SYSTEM
Engaging the Height Restriction System Disengaging the Height Restriction

System
! WARNING
You could be killed or seriously injured if the loader 1 Make sure the parking brake is on, and that the
control is accidentally operated. Make sure that no- transmission is in neutral.
one goes near the machine whilst you fit/remove the
transit strut. 2 Turn isolator tap C to the horizontal position.
4-2-5-8
3 Raise the loader arm to take the weight off the transit
! CAUTION strut A. Stop the engine.
ACCS must be switch OFF when travelling on the road
with the Height Restriction System engaged. 4 Remove the strut:
4-2-3-3
a Release securing strap B.

1 Empty the shovel and raise the loader arm enough to
fit the transit strut A.
b Remove strut.
2 Apply the parking brake, put the transmission in
c Return the strut to its stowage position.
neutral and stop the engine.
3 Fit the strut:
a Remove the strut from its stowage position.
b Place the strut around the ram.
c Secure the strut into position using strap B.
4 Start the engine.
5 Slowly lower the loader arm onto the transit strut.

Stop the movement immediately the weight of the
arm is supported by the strut. C
Note: Extreme care must be taken when lowering the
loader arm onto the transit strut. 'Feather' the lever to
lower the loader arm slowly.

7 Turn isolator tap C to the vertical position to isolate

the loader arm from the hydraulic system.
B
387200
8710-1


71
MAINTENANCE 71
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand this information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it too.
! WARNING Used Oil

Oil
Oil is toxic. If you swallow any oil, do not induce Used engine crankcase lubricants contain harmful
vomiting, seek medical advice. Used engine oil contaminants.
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than Here are precautions to protect your health when handling
necessary. Always use barrier cream or wear gloves to used oil:
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol, 1 Avoid prolonged, excessive or repeated skin contact
diesel fuel or paraffin to clean your skin. with used oils.
INT-3-2-3
2 Apply a barrier cream to the skin before handling
Hygiene used engine oil.
JCB lubricants are not a health risk when used properly 3 Note the following when removing engine oil from
for their intended purposes. skin:
However, excessive or prolonged skin contact can remove a Wash your skin thoroughly with soap and water.
the natural fats from your skin, causing dryness and
irritation. b Using a nail brush will help.
Low viscosity oils are more likely to do this, so take c Use special hand cleansers to help clean dirty
special care when handling used oils, which might be hands.
diluted with fuel contamination.
d Never use petrol, diesel fuel, or paraffin for
Whenever you are handling oil products you should washing.
maintain good standards of care and personal and plant
hygiene. For details of these precautions we advise you to 4 Avoid skin contact with oil soaked clothing.
read the relevant publications issued by your local health
authority, plus the following. 5 Don't keep oily rags in pockets.
Storage 6 Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children. 7 Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers. First Aid - Oil

Waste Disposal Eyes
In the case of eye contact, flush with water for 15 minutes.
All waste products should be disposed of in accordance If irritation persists, get medical attention.
with all the relevant regulations.
Swallowing
The collection and disposal of used oil should be in If oil is swallowed do not induce vomiting. Get medical
accordance with any local regulations. Never pour used advice.
oil into sewers, drains or on the ground.
Skin
Handling In the case of excessive skin contact, wash with soap and
water.
New Oil
Spillage
There are no special precautions needed for the handling
or use of new oil, beside the normal care and hygiene Absorb on sand or a locally approved brand of absorbent
practices. granules. Scrape up and remove to a chemical disposal
area.
Fires
Extinguish with carbon dioxide, dry chemical or foam.
Fire-fighters should use self-contained breathing
apparatus.
8710-1

72
MAINTENANCE 72
SERVICE REQUIREMENTS
Introduction Owner/Operator Support

Your machine has been designed and built to give JCB together with your Distributor wants you to be
maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do
wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your
machine was inspected both at the Factory and by your Distributor's Service Department which is there to help
Distributor to ensure that it reaches you in optimum you!
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as You will have been given the names of the relevant service
specified in this Handbook, are carried out by an contacts at your Distributor when the machine was
approved JCB Distributor at the recommended intervals. installed.
To get the most from your Distributor please help the staff
Maintenance to satisfy you by:
This section of the Handbook gives full details of the 1 Giving your name, address and telephone number.
service requirements necessary to maintain your JCB
machine at peak efficiency. 2 Quoting your machine model and serial number.
To further protect your machine's performance it is 3 Date of purchase and hours of work.
essential your JCB Distributor carries out an initial service
and inspection when the machine is one month old or 4 Nature of the problem.
when it has completed 100 hours of operation (whichever
occurs first). You should notify your Distributor in advance Remember, only your JCB Distributor has access to the
to allow the necessary arrangements to be made. vast resources available at JCB to help support you. In
addition, your Distributor is able to offer a variety of
JCB regularly updates its Distributors advising them of any programmes covering Warranty, Fixed Price Servicing,
product developments, changes in specifications and Safety Inspections, including weight tests, covering both
procedures. Therefore only a JCB Distributor is fully able legal and insurance requirements:
to maintain and service your machine.
At the rear of this Handbook is a Service Record Sheet Service/Maintenance Agreements

which will enable you to plan your service requirements
and keep a service history record. This record sheet To help plan and spread the costs of maintaining your
should be dated, signed and stamped by your Distributor machine, we strongly recommend you take advantage of
each time your machine is serviced. the many Service and Maintenance Agreements your
Distributor can offer. These can be tailor made to meet
Remember, if your machine has been correctly your operating conditions, work schedule etc.
maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced. Please consult your JCB Distributor for details.
8710-1

73
MAINTENANCE 73
GENERAL SAFETY
When working on a Wheeled Loader, the machine If working with the loader arms raised, fit the loader arm
must be made safe before carrying out any servicing. safety strut.
Position the machine on firm level ground. Engage the If working on an area not reachable when standing on the
parking brake. ground, use a suitable stable working platform.
Chock both sides of all four wheels. ! WARNING

Maintenance must be done by suitably qualified
Make sure the transmission is in neutral.
personnel. Before attempting any maintenance work,
make sure the machine is safe. Park on level ground.
Lower the loader arms to the ground; make sure that the
If it is necessary to work with the loader arm raised,
shovel/attachment is flat on the ground to prevent
then the loader arm safety strut must be fitted. See
accidental movement.
Loader Arm Safety Strut in MAINTENANCE section.
The articulation lock must be fitted if you are
Fit the articulation lock.
inspecting and/or doing any maintenance work in the
articulation danger zone. See Installing the
Switch OFF the engine and remove the starter key.
Articulation Lock in MAINTENANCE section.
4-3-1-1/1
Operate the controls to vent residual pressure.
SERVICE SCHEDULES
A badly maintained machine is a danger to the operator 100 Hours

and the people working around him. Make sure that the
regular maintenance and lubrication jobs listed in the Do the daily checks plus:
schedules are done to keep the machine in a safe and
efficient working condition. Check - Adjust/Replenish as necessary Page
The schedules are based on machine running hours. 2 Differential oil levels 97
Keep a regular check on the hourmeter readings. Do not 3 Hub oil levels 98
use a machine which is due for a service. Make sure any 4 Tyre pressures and condition 151
defects found during the regular maintenance checks are
rectified immediately. Lubricate Page
10 Hours - Daily Checks 1 Loader end pivots 79

2 Steer ram pivots 80
Check - Adjust/Replenish as necessary Page 3 Centre pivot 80
4 Rear axle pivots 80
1 Engine oil level 85
2 Coolant level 87
3 Transmission oil level 96
4 Hydraulic fluid level 99
5 Instrument panel operation
6 Machine condition generally
7 Windscreen washer fluid level 105
50 Hours
Do the daily checks plus:
Drain Page
1 Fuel filter 93
8710-1

74
MAINTENANCE 74
SERVICE SCHEDULES
(continued)
500 Hours 1000 Hours

Do the daily checks through to 100 hours plus: Do the daily checks through to 500 hours plus:
Check - Adjust/Replenish as necessary Page Check - Adjust/Replenish as necessary Page
1 Engine air cleaner hose security 1 Engine valve clearances $

2 Antifreeze strength 87 2 Propshaft security
3 Fuel sedimenter 94 3 Battery terminals for condition/tightness
4 Engine mount security 4 ROPS/FOPS structures 77
5 Compressor belt tension/condition 91 5 Fan belt tension/condition 90
6 Parking brake operation 50 6 Bevel ring gear deflection plunger
7 Transmission and axles - leaks
8 Hoses & pipework- damage or leaks Lubricate Page
9 Wiring - chaffing
10 Battery charge condition 1 Propshaft and universal joints 81
11 Seat belt security/condition 82
Change Page
Clean Page
1 Transmission oil 96
1 Axle breathers 2 Transmission strainer/filter 96
2 Cab heater intake filter 83 3 Differential oil 97
3 Cab recirculation filter 83 4 Hub oil 98
Lubricate Page 2000 Hours

1 Centre propshaft slide 81 Do the daily checks through to 1000 hours plus:
2 All hinges
Check Page
Change Page
1 Engine valve clearances
1 Engine oil and filter # 86
2 Engine air cleaner outer element ‡ 84 Clean Page
3 Engine fuel filter 93
4 Hydraulic oil filter 100 1 Hydraulic suction strainer
5 Coolant filter 89
Change Page
Test Page
1 Engine air cleaner inner element ‡ 84
1 Coolant 2 Coolant 89
3 Hydraulic fluid (and sample)
4 Hydraulic filler cap
Notes:
† when working in arduous conditions, grease and
operate the locking pins every 10 hours.
# CH4 oil and Stratopore filters MUST be used,

otherwise change at 250 hours.
‡ As required, in arduous conditions.
$ Ist 1000 hours only.
8710-1

75
MAINTENANCE 75
ARTICULATION LOCK
Installing the Articulation Lock Removing the Articulation Lock

! WARNING ! WARNING
Make sure the articulation safety lock is fitted before Always make sure the articulation safety lock has been
transporting the machine. The articulation safety lock removed before attempting to drive the machine. The
must also be fitted if you are inspecting and/or doing machine cannot be steered with the articulation lock
any maintenance work in the articulation danger zone. fitted.
16-3-1-3 16-3-1-4
The articulation lock is fitted with the machine in a 'straight

ahead' position. 1 Remove pins A and B.
1 Steer the machine to bring the front and rear wheels 2 Remove articulation locking bar C, stow pins A and B
in a straight line. in the bar.
2 Apply the parking brake, put the transmission in 3 Return the articulation locking bar to the tool stowage
neutral. box.
3 Remove articulation locking bar C from tool stowage

box. Fit articulation locking bar into position with pin
A and then pin B. If pin B will not fit, turn steering
wheel slightly to align hole.
4 Stop the engine.
A
B
S269750
8710-1

76
MAINTENANCE 76
LOADER ARM SAFETY STRUT
Installing the Safety Strut Removing the Safety Strut

! WARNING ! WARNING
Raised loader arms can drop suddenly and cause You could be killed or injured if the loader control is
serious injury. Before working under raised loader accidentally operated. Make sure no-one comes near
arms, fit the loader arm safety strut. the machine while you remove the safety strut.
2-1-1-6 2-3-1-3
! WARNING
You could be killed or seriously injured if the loader 1 Make sure the parking brake is on, and that the
control is accidentally operated. Make sure that no- transmission is in neutral.
one goes near the machine whilst you fit the safety
strut. 2 Raise the loader arm to take the weight off the safety
16-3-1-5 strut A. Stop the engine.
1 Empty the shovel and raise the loader arm enough to 3 Remove the strut:
fit the safety strut A.
a Release securing strap B.
neutral and stop the engine. b Remove safety strut.
3 Fit the strut: c Return the safety strut to the tool stowage box.
a Remove the strut from the tool stowage box.
b Place the strut around the ram.
c Secure the strut into position using strap B.
4 Start the engine.
5 Slowly lower the loader arm onto the safety strut.

Stop the movement immediately the weight of the
arm is supported by the strut.
Note: Extreme care must be taken when lowering the

loader arm onto the safety strut. 'Feather' the lever to
lower the loader arm slowly.
S270300
8710-1

77
MAINTENANCE 77
ROPS/FOPS STRUCTURE
Checking the ROPS/FOPS Structure

! WARNING
The machine is fitted with a Roll Over Protection
Structure (ROPS) and a Falling Objects Protection
Structure (FOPS). You could be killed or seriously
injured if you operate the machine with a damaged or
missing ROPS/FOPS. If the ROPS/FOPS has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9/3
1 Check the structure for damage.
2 Make sure that all the ROPS/FOPS mounting bolts A A

are in place and undamaged.
3 Make sure that the ROPS/FOPS mounting bolts A are

tightened to the correct torque setting. This should A
be 330 Nm (243 lbf ft).
A
A
S203280
BRAKES
(446 Only)
Adjusting the Parking Brake
1 Disengage the parking brake (lever horizontal).
2 Turn adjuster E clockwise, half a turn.
3 Test the parking brake. See Testing the Parking

Brake (OPERATION section).
4 If the brake fails the test, repeat steps 1 to 3.
Note: If after completing the above steps, the parking

brake does not pass the testing procedure, do not use the
machine. Contact your JCB Distributor. E
385720
8710-2

78
MAINTENANCE 78
ENGINE COVERS
Opening the Engine Covers Closing the Engine Covers

! WARNING
Engine 1 Pull handle B down and inwards.
The engine has rotating parts. Do not open the engine
cover while the engine is running. Do not use the 2 Make sure the panel is latched.
machine with the cover open.
INT-2-1-6

A
2 Pull handle A. It is recommended that the panels are
kept locked.
3 Pull handle B out and up, allow the gas-strut to open

the panel. B
397180
REAR GRILLE
Opening the Rear Grille
1 Pull the handle D to unlatch the rear grille.

D
2 The rear grille can then be opened on its hinges.
Closing the Rear Grille

1 Close the rear grille and press in latch D.
2 Make sure the latch is secure.
397190
8710-1

79
MAINTENANCE 79
GREASING
! WARNING The machine must be greased regularly to keep it working

efficiently. Regular greasing will also increase the
Make the machine safe before working underneath it.
machine's working life.
Park the machine on level ground and lower the
attachments, (if it is necessary to work with the loader
Grease should be applied with a grease gun, normally two
arms raised, the loader arm safety strut must be
strokes of the gun should be sufficient. Stop the greasing
fitted). See Loader Arm Safety Strut in MAINTENANCE
procedure when fresh grease appears at the joint. Use
section. Engage the parking brake, put the
the recommended grease. See Fluids, Capacities and
transmission in neutral and stop the engine. Chock
Lubricants in MAINTENANCE section.
both sides of all four wheels. If you are working near
the articulation danger zone, fit the articulation safety
In the following illustrations, the grease points are
lock. See Articulation Lock in MAINTENANCE section.
4-3-2-1/1 numbered. Count off the grease points as you apply
grease to each one. Refit the dust caps after greasing.
4 Ram Loader Arm Pivot Points (HT)

Total of 20 grease points (5 to 24)
Shovel Pivot Pins

Total of 4 grease points. (1 to 4) $£
%^
@!
&*
6 09
5 ()
78
1 21 22
21
43 23 24
417140
Z Bar Loader Arm Pivot Points (ZX)

Total of 10 grease points (4 to 13)
Shovel Pivot Pins

Total of 3 grease points. (1 to 3)
7
6
89
5 0!
@£
1
4
23 S262770
8710-2

80
MAINTENANCE 80
GREASING
(continued)
Centre Pivot and Steering Ram Rear Axle Pivots

Total of 7 grease points Total of 2 grease points
! WARNING
Make sure the articulation safety lock is fitted before
greasing the centre pivot.
16-3-2-2
45
2 6
7
1 2
S269950 397070
8710-1

81
MAINTENANCE 81
GREASING
(continued)
Propshafts ! WARNING
Make the machine safe before working underneath it.
Total of 7 grease points
Park the machine on level ground and lower the
attachments, (if it is necessary to work with the loader
arms raised, the loader arm safety strut must be
fitted). See Loader Arm Safety Strut in MAINTENANCE
section. Engage the parking brake, put the
transmission in neutral and stop the engine. Chock
both sides of all four wheels. If you are working near
the articulation danger zone, fit the articulation safety
lock. See Articulation Lock in MAINTENANCE section.
4-3-2-1/1
3 4 5 6 7
1 2
S201770
Cab Door Hinges

When greasing the cab door hinges, open the door and
stand as shown.
S270310
8710-1

82
MAINTENANCE 82
CHECKING FOR DAMAGE
Inspect steelwork for damage. Note damaged paintwork Check all shovel teeth for damage and security.
for future repair.
Check all lamp lenses for damage.
Make sure all pivot pins are correctly in place and secured
by their locking devices. Inspect the tyres for damage and penetration by sharp
objects.
Ensure that the steps and the handrails are undamaged
and secure. Check that all safety decals are in place and undamaged.
Fit new decals where necessary.
Check for broken or cracked window glass. Replace
damaged items.
CLEANING THE MACHINE
Clean the machine using water and/or steam. Pay Avoid using neat detergent - always dilute detergents as
particular attention to the underside. Do not allow mud to per the manufacturer's recommendations, otherwise
build up on the engine and transmission. Make sure the damage to the paint finish may occur.
radiator grille is not clogged up.
Rinse off all the detergent with water.
It is important to note that excessive power washing can
cause damage to the seals or bearings. Take care during ! CAUTION
routine machine washing not to direct high power water
jets directly at oil seals or universal joints. Do not steam clean the batteries.
4-3-1-4
Note: The machine must always be greased after pressure

washing or steam cleaning.
SEAT BELT
Checking the Seat Belt Security and

Condition
! WARNING
A JCB approved seat belt is fitted to your machine. When checking the seat belt, look for signs of fraying and
Replace it with a new one if it is damaged, if the fabric stretching. Make sure the stitching is not loose or
is worn, or if the machine has been in an accident. Fit damaged. Make sure the buckle assembly is working
a new seat belt every three years regardless of correctly and not damaged. Fit a new seat belt every
condition. three years.
2-3-1-8/1
Make sure the belt mounting bolts are undamaged,
correctly fitted and tightened.
8710-1

83
MAINTENANCE 83
CAB HEATER/ FILTER
Cleaning the Intake Filter ! CAUTION

The machine must not be run with the intake filter(s)
! CAUTION removed otherwise damage will be caused to the
The filter may be filled with dust. Wear goggles and a evaporator matrix.
0029
face mask when removing the filter.
2-3-3-6
1 Park the machine on level ground. Engage the

parking brake. Put the transmission in neutral. Lower
the attachments to the ground. Stop the engine.
Remove the starter key.
2 To gain access to the cab heater air filter, unlock B, C

open panel C. Turn fastener A one quarter turn anti-
clockwise and remove cover D.
B
3 Remove the filter, shake out the loose dust and clean
using low pressure compressed air. Renew the filter if
damaged.
Note: Make sure to replace the filter in the correct A

location. The short filter must always be fitted in the rear
slot.
D
4 Refit cover D, Turn fastener A one quarter turn
clockwise. Close panel C and lock B.
Cleaning the Recirculation Filters 397200
! CAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6
H F
1 Park the machine on level ground. Engage the G
parking brake. Put the transmission in neutral. Lower
the attachments to the ground. Stop the engine.
Remove the starter key.
2 To gain access to the cab recirculation air filter F,

turn fastener G one quarter turn anti-clockwise and
remove cover H.
3 Remove the filter F, shake out the loose dust and

clean using low pressure compressed air. Renew the
filter if damaged.
4 Wash filter F in warm water with mild detergent.

Rinse all trace of detergent from filter. make sure filter
is dry before refitting.
5 Refit filter F and cover H, make sure bottom lug on

cover is located. Push in and turn fastener G one
quarter turn clockwise. Make sure that the cover is
secure. A350480
8710-1

84
MAINTENANCE 84
ENGINE AIR FILTER
Changing the Elements

Note: In a dusty working environment, the outer element 3 If changing the inner element, disconnect the filter
may have to be renewed more frequently than the service induction hose J and cover the end to prevent dust
schedule recommendation. A new inner element must be getting into the engine.
fitted at latest every third time the outer element is
changed. As a reminder, mark the inner element with a felt 4 Release latches A and remove cover B. Gently
tip pen each time you change only the outer element. DO remove the outer element C by moving the end up
NOT attempt to wash or clean elements - they must be and down or by twisting to disengage the seal. Take
renewed. care not to tap or knock the element as you remove
it. If necessary, remove the inner element D.
! CAUTION
5 Clean inside canister E, particularly the outlet tube on
The outer element must be renewed immediately if the
which the elements seal. Clean dust valve F.
warning light on the instrument panel illuminates.
2-3-3-1
6 Check the new elements before fitting, discard if
! CAUTION damaged. Smear the seals G and H with engine oil
or, preferably, silicone oil then carefully install the
Do not run the engine when the outer element has
elements onto the outlet tube. Apply firm pressure to
been removed.
16-3-3-1 the outer rim of the element, not the soft centre.
1 Apply the parking brake, put the transmission in 7 Refit cover B making sure it is properly located then
neutral and stop the engine. secure latches A. Make sure that dust valve F is at
the bottom.
2 Open the engine cover on the right side of the
machine. 8 Connect the induction hose J. Make sure the air filter
blocked switch connector is fitted. Check all hoses
for condition and tightness.
J E
D
C A
B
A
F
H
397220
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85
MAINTENANCE 85
ENGINE OIL AND FILTER
Checking the Oil Level

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

attachments to the ground.
2 Stop the engine. Put the transmission in neutral and

remove the starter key.
3 Open the right side engine cover.
4 Check that the oil level is between the two marks on

the dipstick A.
5 If necessary, add the recommended oil through the

filler point B. See Fluids, Capacities and Lubricants
in MAINTENANCE section.
6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.
397060
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86
MAINTENANCE 86
ENGINE OIL AND FILTER

(continued)
Changing the Oil and Filter

! WARNING
Make the machine safe before getting beneath it. 9 Add clean engine oil to the new filter canister. Allow
Lower the attachments to the ground; engage the time for the oil to pass through the filter element.
parking brake; remove the starter key, disconnect the
battery. 10 Smear the seal D on the new filter canister with clean
2-3-2-2 engine oil.
! WARNING 11 Screw in the new filter canister until it just contacts

Hot oil and engine components can burn you. Make the filter head.
sure the engine is cool before doing this job.
2-3-3-2 12 Turn the filter a further 3/4 of a turn.
13 Fill the engine with the recommended oil, to the MAX

1 Park the machine on level ground and lower the mark on the dipstick, through the filler point. Wipe off
attachments to the ground. any spilt oil, refit the filler cap and make sure it is
secure. Close the engine covers.
2 Stop the engine. Put the transmission in neutral and
remove the starter key. 14 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
3 Open the left and right side engine covers. warning light is extinguished.
4 Place a suitable container beneath the drain plug A Note: To make sure the engine will not start, remove the
(to catch the oil). engine shut-off solenoid fuse. See Fuses in
MAINTENANCE section.
5 Remove drain plug and its 'O' ring and drain the oil
from the sump. Renew the 'O' ring. 15 Refit the engine shut-off solenoid fuse and start the
engine. Check for leaks. When the engine has cooled,
6 Clean and refit the drain plug and its 'O' ring and check the oil level.
tighten the drain plug to 34 Nm (25 lbf ft). DO NOT
OVERTIGHTEN.
7 Clean the area around the filter head. Unscrew the

filter canister C. Remember that it will be full of oil.
8 Clean the filter head. Make sure that the ‘O’ ring is
removed. 0 ! @
D
A
S270270 397030
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87
MAINTENANCE 87
ENGINE COOLING SYSTEM
! WARNING Coolant Mixtures

The cooling system is pressurised when the coolant is
To prevent the coolant freezing in cold conditions,
hot. Hot coolant will burn you. Make sure the engine
antifreeze must be added. JCB Four Seasons Antifreeze
is cool before checking the coolant level or draining
and Summer Coolant will give protection down to the
the system.
2-3-3-3 temperatures shown in the table.
Checking the Coolant Level Antifreeze Solution Starts to freeze at
1 Park the machine on level ground. Engage the 55% -36°C (-33°F)
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the right side Never use less than a 50% solution otherwise there will
engine cover. not be enough corrosion protection.
2 Check that the coolant is visible in the header tank A. Never use more than 60% solution otherwise the cooling
The level should be between 1/3 and 2/3 full. If not, system may be damaged.
continue with steps 3 to 5.
Leave the antifreeze in all the year round as it gives
3 Close the engine cover. Top up the coolant system protection against corrosion.
through the filler cap. Access to the filler cap is
through a hole in the engine cover above the filler Check the strength of antifreeze solution at least once a
cap. year, preferably at the start of the cold period. Always
renew the antifreeze every two years.
4 Refit the filler cap and make sure it is tight.
A 50% antifreeze mixture should be used even if frost
5 Run the engine for a while to raise the coolant to protection is not needed. This gives protection against
working temperature and pressure. Stop the engine corrosion and raises the coolant's boiling point.
and check for leaks.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling neat or diluted antifreeze.
7-3-4-4
Anti-corrosion Additives
To provide suffient corrosion protection, supplemental
coolant additive (SCA) must be added to the coolant
mixture. The coolant filter provides the required amount of
SCA, provided the filter is replaced at regular intervals.
397210
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88
MAINTENANCE 88

(continued)
Draining and Refilling the Coolant 7 Fill the system slowly with the mixture to prevent air
locks. Wait 2 to 3 minutes to allow air to be vented
1 Park the machine on level ground. Engage the and top up to the header tank to 1/3 full. Do not fit
parking brake. Put the transmission in neutral. Stop the filler cap at this stage.
the engine and let it cool down. Open the left side
engine cover. 8 Run the engine for 5 minutes at the normal running
temperature. Stop the engine and allow to cool.
! WARNING
9 Drain the cooling system, checking that the coolant is
Hot Coolant not dirty. If it is, repeat the flushing process (steps 6
The cooling system is pressurised when the engine is to 9).
hot. Hot coolant can spray out when you remove the
filler cap. Let the system cool before removing the 10 Refill the system as described at step 7 but using
filler cap. To remove the cap; turn it to the first notch pre-mixed water/antifreeze solution (as specified in
and let the steam pressure escape, then remove the Coolant Mixtures). Do not overfill. Fit the filler cap.
cap.
INT-3-2-9/1 Note: A 50% antifreeze mixture must be used even if frost
protection is not needed. This gives protection against
2 Access to the filler cap is through a hole in the engine corrosion and raises the coolant’s boiling point.
cover above the filler cap. Carefully loosen cap. Let
any pressure escape. Remove the cap. 11 Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine
! WARNING and check for leaks.
Keep your face away from the drain hole when
removing the drain plug. Note: Make sure the heater control is in the hot position
2-3-3-4 before running the engine. This will ensure that the coolant
mixture circulates through the entire cooling system.
3 Remove the bottom hose and drain the coolant.
4 Flush the system using clean water.
5 Refit bottom hose.
6 Prepare a mixture of water and sodium carbonate.
Note: Use 1.0 lb (0.5 kg) of sodium carbonate for every 23

litre (5.0 UK Gal, 6.0 US Gal) of water.
8710-1

89
MAINTENANCE 89

(continued)
Changing the Coolant Filter

1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the left side
engine cover.
! WARNING
Hot Coolant
The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the
radiator cap. Let the system cool before removing the
radiator cap. To remove the cap; turn it to the first
notch and let the steam pressure escape, then
remove the cap.
INT-3-2-9
2 Carefully loosen filler cap. Let any pressure escape.

Remove the cap.
3 Close taps A on either side of the filter to prevent loss

of coolant.
4 Remove the coolant filter by unscrewing anti-

clockwise.
5 Clean the filter head area.
6 Smear clean oil on the new coolant filter seal.
7 Screw on the filter until it just contacts the filter head.
8 Turn the filter a minimum further 3/4 of a turn.
9 Open both taps A and replace filler cap.
A
6 A
A260410 397020
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90
MAINTENANCE 90
ENGINE DRIVE BELT
! WARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
1 Park the machine on level ground.
2 Apply the parking brake, put the transmission in A

neutral and stop the engine. C
3 Open the left side engine cover.
B
4 Inspect the belt for damage.
Cracks across the belt width A are acceptable.

C
Cracks across the belt which intersect those in the
direction of the belt length B are not acceptable. S209630
Renew the belt if it has unacceptable cracks or if it is

frayed or has pieces of material missing as at C.
5 Check the Belt Tension.
The maximum deflection on the longest run of the

belt as at D should be 9.5 to 12.7 mm (0.375 to 0.5
in). If the deflection is excessive, see your JCB
distributor for drive belt replacement.
6 Close and lock the left side engine cover.

D
S209640
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91
MAINTENANCE 91
AIR CONDITIONING COMPRESSOR DRIVE BELT
Adjusting the Compressor Belt

! WARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
1 Park the machine on level ground.

neutral and stop the engine. B C
3 Open the right side engine panel.

A
4 Loosen pivot bolt A (Not shown). Loosen bolts B and
C.
5 Adjust the belt by positioning the compressor to give

5 mm (3/16 in) slack at the mid point of the longest
run.
6 Tighten bolts B and C. Tighten pivot bolt A.
7 Close and lock the engine panel.
! WARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the 397100
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.
4-3-4-1/2
8710-1

92
MAINTENANCE 92
FUEL SYSTEM
Types of Fuel Low Temperature Fuels

Use good quality diesel fuel to get the correct power and Special winter fuels may be available for engine operation
performance from your engine. The recommended fuel at temperatures below 0°C (32°F). These fuels have a
specification is given below. lower viscosity. They also limit wax formation in the fuel at
low temperatures. (Wax forming in the fuel can stop the
Cetane Number: 45 (minimum) fuel flowing through the filter).
Viscosity: 2.5/4.5 centistokes at 40°C (104°F)
Density: 0.835/0.855 kg/litre Flow improvers may also be available. These can be
(0.872/0.904 lb/pint) added to the fuel to reduce wax formation.
Sulphur: 0.5% of mass (maximum)
Distillation: 85% at 350°C (662°F) Petrol
Cetane Number
! WARNING
Do not use petrol in this engine. Do not mix petrol with
Indicates ignition performance. Fuel with a low cetane the diesel fuel. In storage tanks the petrol could rise
number can cause cold start problems and affect to the top and form flammable vapours.
INT-3-1-6
combustion.
Viscosity Advice
Is the resistance to flow. If this is outside limits, the If you have to use non-standard fuels, contact your JCB
engine performance can be affected. distributor for advice on engine adjustments and oil
change periods.
Density
Fatty Acid Methyl Ester Fuels as a
Lower density will reduce engine power. Higher density replacement for Diesel Fuels
will increase both engine power and exhaust smoke.
Fuel resources such as Rape Methyl Ester and Soybean
Sulphur Methyl Ester, collectively known as Fatty Acid Methyl
Esters are being used as altenatives and extenders for
High sulphur content can cause engine wear. (High mineral oil.
sulphur fuel is not normally found in North America,
Europe or Australia.) If you have to use high sulphur fuel Fatty Acid Methyl Esters must conform to certain
you must also use a highly alkaline engine lubricating oil; standards to be of acceptable quality, just as mineral oils
do at present.
or change the normal oil more frequently.
Low sulphur fuels are commonly used throughout the Consult your JCB Distributor for advice about the use of
world. These fuels contain fewer lubrication additives. The Fatty Acid Methyl Ester Fuels, as improper application
fuel injection pumps (with exception of 160TW, Euro 1 may impair engine performance.
engine) are lubricated by the fuel; therefore using low
sulphur fuel may, in the long term, affect the pump. ! WARNING
Diesel fuel is flammable; keep naked flames away from
If you have to use a low sulphur fuel your are advised to the machine. Do not smoke while refuelling the
use a lubrication additive as recommended by your fuel machine or working on the engine. Do not refuel with
supplier. the engine running. There could be a fire and injury if
you do not follow these precautions.
Distillation INT-3-2-2
This indicates the mixture of different hydrocarbons in the Filling the Tank
fuel. A high ratio of lightweight hydrocarbons can affect
the combustion characteristics. At the end of every working day, fill the tank with the
correct type of fuel. This will prevent overnight
Fuel Standards condensation from developing in the fuel.
Consult your fuel supplier or JCB distributor about the We recommend that, if possible, you lock the fuel cap to
suitability of any fuel you are unsure of. prevent theft and tampering.
8710-1

93
MAINTENANCE 93
FUEL SYSTEM
(continued)
Draining the Fuel Filter Changing the Fuel Filter Element

1 Apply the parking brake, put the transmission in 1 Apply the parking brake, put the transmission in
neutral and stop the engine. neutral and stop the engine.
2 Open the right side engine cover. 2 Open the right side engine cover also remove the
forward fixed engine cover panel.
3 Drain off any water in the element B by turning valve
A 4 turns anti-clockwise until the valve drops down 3 Unscrew the filter element, the element is hand tight
25 mm (1.0 in). but may require a strap wrench to remove. The filter
will be full of fuel.
4 Push up valve and turn clockwise until closed. Do not
over tighten. 4 To assist with bleeding, fill the filter element with fuel
before fitting. Install filter element, hand tight only.
5 Close and lock the engine cover. Check for leaks.
! CAUTION 5 Bleed the fuel system. See Bleeding the Fuel

System in MAINTENANCE section.
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
6 Refit the engine panel, close and lock the engine
the system must be bled to remove any air.
2-3-3-11 cover.
S269030
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94
MAINTENANCE 94
FUEL SYSTEM
(continued)
Draining the Sedimenter Bowl Cleaning the Sedimenter Bowl

1 Apply the parking brake, put the transmission in If bowl B contains sediment carry out the following:-
1 Hold the bowl B and unscrew domed nut C.
2 Open the right side engine cover.
2 Remove the bowl, and wash in clean fuel.
3 Drain off any water in the bowl by turning tap A and
slacken screw E. 3 Clean strainer D.
4 Make sure tap A is turned off and secure. Tighten 4 Refit the bowl. Make sure the gasket is in good
screw E. condition and positioned correctly.
5 Close the right side engine cover. 5 Re-tighten nut C, taking care not to over-tighten.
! CAUTION 6 Bleed the fuel system. See Bleeding the System

(MAINTENANCE section).
Running the engine with air in the system could
the system must be bled to remove any air.
2-3-3-11
E C
A B
S261720
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95
www.WorkshopManuals.co.uk 95
MAINTENANCE
BLEEDING THE FUEL SYSTEM
! CAUTION
Running the engine with air in the system could 4 Open bleed screw A.
the system must be bled to remove any air. 5 Operate the priming plunger B until air free fuel flows
2-3-3-11 from the bleed screw. Tighten the bleed screw.
If the engine fails to start, misfires or if any part of the fuel ! WARNING
system has been disconnected or emptied, bleed the To bleed the injectors you must turn the engine. When
system as follows: the engine is turning, there are parts rotating in the
engine compartment.
Note: Small amounts of air will be vented automatically at
the injection pump. Manual bleeding should not be Before starting this job make sure that you have no
required after changing the filters if they are filled with fuel loose clothing (cuffs, ties, etc) which could get caught
before fitting. in rotating parts.
1 Apply the parking brake, put the transmission in When the engine is turning, keep clear of rotating
neutral and stop the engine. parts.
2-3-3-8
2 Make sure that there is enough fuel in the fuel tank.
6 Bleed the injectors
3 Open the right side engine cover. a Slacken one of the injector feed pipe nuts D.
! WARNING b Crank the engine, when air free fuel flows from the
Hot oil and engine components can burn you. Make connection, tighten the nut.
sure the engine is cool before doing this job. Bleeding
a hot engine could cause fuel to spill on to a hot c Repeat steps a and b at each injector in turn until
exhaust manifold creating a danger of fire. the engine runs smoothly.
13-3-1-16
7 Close and lock the engine cover.
D A
397090
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96
MAINTENANCE
TRANSMISSION
Checking the Oil Level (Engine Running) Changing the Oil and Filter
Note: The transmission oil level should be checked only ! WARNING
when the oil is at the correct working temperature. Make the machine safe before getting beneath it.
Lower the attachments to the ground; engage the
1 Park the machine on level ground. parking brake; remove the starter key, disconnect the
battery.
2 Apply the parking brake, put the transmission in 2-3-2-2
neutral.
3 Open the left side engine cover. Remove, wipe and 1 Place a suitable container beneath the transmission.
replace the dipstick A. (To catch the oil).
Note: Turn ‘T’ handle D, two full turns anti-clockwise to 2 Remove the dipstick A and drain plug B.
release the dipstick. Turn ‘T’ handle D, two full turns
clockwise to fasten in position. Check that the dipstick is 3 Drain the oil. Clean and refit drain plug B.
secure.
4 Unscrew and discard old filter C. Clean the mounting
4 Make sure the oil is at the correct mark on the face and lubricate the seal on the new filter with clean
dipstick. torque converter fluid.
5 If necessary, add recommended oil at dipstick/filler 5 Fit the new filter C hand tight only.
point A.
6 Fill the system with new oil at dipstick/filler point A.
Note: The transmission may overheat if the oil level is
above the HOT mark. Note: Do not fill past the top mark on the dipstick.
6 Close and lock the engine cover.
D
A
B
397040 A337470
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97
MAINTENANCE
FRONT AND REAR AXLES
Checking the Differential Oil Level Draining and Refilling the Differential Oil
! WARNING ! WARNING
Make the machine safe before getting beneath it. Make the machine safe before getting beneath it.
Lower the attachments to the ground; engage the Lower the attachments to the ground; engage the
parking brake; remove the starter key, disconnect the parking brake; remove the starter key, disconnect the
battery. battery.
2-3-2-2 2-3-2-2
! CAUTION 1 Clean the area around fill/level plug A.

The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil 2 Remove fill/level plug A and its seal.
in the axle will be given.
16-3-5-3 3 Place a suitable container beneath the brain plug B
(to catch the oil).
1 Clean the area around fill/level plug A.
4 Remove drain plug B. Allow the oil to drain fully.
2 Remove fill/level plug A and its seal, oil should be
level with the bottom of the hole. ! CAUTION
Oil will gush from the hole when the drain plug is
3 Top up with the recommended oil if necessary.
removed. Keep to one side when you remove the plug.
2-3-4-2
4 Clean and refit fill/level plug A and its seal. Tighten to
85 Nm (60 lbf ft). 5 Clean and refit drain plug B and its seal. Plug B is
magnetic, make sure all debris is removed. Tighten to
85 Nm (60 lbf ft).
6 Fill the axle with the recommended oil through

fill/level plug A.
7 Clean and refit fill/level plug A and its seal. Tighten to

85 Nm (60 lbf ft).
B S217950
8710-1

98
MAINTENANCE
FRONT AND REAR AXLES

(Continued)
Checking the Hub Oil Level Draining and Refilling the Hub Oil
! WARNING ! WARNING
Make the machine safe before getting beneath it. Make the machine safe before getting beneath it.
Lower the attachments to the ground; engage the Lower the attachments to the ground; engage the
parking brake; remove the starter key, disconnect the parking brake; remove the starter key, disconnect the
battery. battery.
2-3-2-2 2-3-2-2
1 Make sure the OIL LEVEL mark on the hub is 1 Make sure fill/drain plug A is at the bottom, as shown
horizontal, as shown at B. at C.
2 Clean the area around fill/drain plug A. 2 Clean the area around fill/drain plug A.
3 Remove fill/drain plug A and its seal, oil should be 3 Remove fill/drain plug A and its seal, drain the oil into
level with the bottom of the hole. a suitable container. Allow the oil to drain fully.
4 Top up with the recommended oil if necessary. ! CAUTION

5 Clean and refit fill/drain plug A and its seal. Tighten to There will be no oil in the hub when the machine is
85 Nm (60 lbf ft). driven forward. Only drive the machine forward one
quarter revolution of the wheel. Do not drive the
Note: The hubs must be treated separately, a total of four machine more than is necessary.
4-3-5-1
hubs.
4 Drive the machine slowly forward to bring the OIL
LEVEL mark on the hubs into the horizontal position,
as shown at B.
5 Fill the hub with the recommended oil through

fill/drain plug A, until oil starts to dribble out.
6 Clean and refit fill/drain plug A and its seal. Tighten to

85 Nm (60 lbf ft).
B Note: The hubs must be treated separately, a total of four

hubs.
A
C
S269300
A
S269040
8710-1

99
MAINTENANCE
HYDRAULIC SYSTEM
! WARNING Hydraulic Tank Cap

Fine jets of hydraulic fluid at high pressure can
The hydraulic tank breather (and filter) forms an integral
penetrate the skin. Do not use your fingers to check
part of the hydraulic tank cap B. Replace the cap (and
for hydraulic fluid leaks. Do not put your face close to
breather filter) with a new one at the recommended
suspected leaks. Hold a piece of cardboard close to
interval.
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates
The cap incorporates a side mounted barrel lock that is
your skin, get medical help immediately.
INT-3-1-10/1 operated by the ignition/door key. It is important to note
that seal C must be in good condition and correctly
Checking the Fluid Level installed in the cap.

neutral, lower the shovel/attachment to the ground. Screw the cap onto the filler neck until hand tight. Use the
Make sure it is flat on the ground. Stop the engine. ignition/door key to lock the cap - note that the key can
only be removed when in the ‘locked’ position. Once the
2 The level should be visible in the sight glass A. key has been removed, the cap will simply rotate on the
thread.
3 If necessary, top up with hydraulic fluid.
To Remove the Cap
4 Open the right side top step. Open filler cap B. To remove the cap from the filler neck, the key must be
reinserted and the cap unlocked.
5 Top up the system with hydraulic fluid. See Fluids,
Capacities and Lubricants (MAINTENANCE
section).
6 Refit filler cap B. Make sure it is secure. Close the

right side top step.
! CAUTION
If the fluid in the tube appears cloudy, then water or air
has entered the system. The hydraulic pump could be
severely damaged if the machine is operated. Contact
your JCB distributor immediately.
2-3-4-3
A B
A260480 S269730
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100
MAINTENANCE
HYDRAULIC SYSTEM
(continued)
Changing the Filter Element

! WARNING
Make the machine safe before getting beneath it.
Lower the attachments to the ground; engage the
parking brake; remove the starter key, disconnect the
battery.
2-3-2-2
1 Open the right side top step.
2 Remove hydraulic tank cap.
3 Unscrew and remove nuts A, cover plate D and seal

E.
4 Pull out the complete element assembly F and the

seal.
5 Remove the nut and spring K. Remove the filter

element L from the spindle and clean magnets J.
6 Fit the new element L and the new seals G and H.
7 Replace the cover plate D and tighten nuts A to 7 Nm

(5 lbf ft).
8 Top up the system with hydraulic fluid. See Fluids,

Capacities and Lubricants (MAINTENANCE
section).
9 Refit filler cap. Make sure it is secure. Close the right

side top step.
J
A
H
D G
K
S119480
8710-1

101
MAINTENANCE
BATTERY
Warning Symbols ! WARNING

Battery
The following warning symbols may be found on the A battery with frozen electrolyte can explode if it is
battery. used or charged. Do not use a machine with a frozen
battery. To help prevent the battery from freezing,
keep the battery fully charged.
Symbol Meaning INT-3-1-7
! WARNING
Keep away from children. Battery Terminals
. The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
A289230
When connecting the battery, connect the earth (-)

lead last.
Shield eyes. When disconnecting the battery, disconnect the earth

(-) lead first.
A289260 INT-3-1-9
! CAUTION
No smoking, no naked flames, Do not disconnect the battery while the engine is
no sparks. running, otherwise the electrical circuits may be
damaged.
A289280 INT- 3- 1-14
! WARNING
Explosive Gas Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
A289250 INT-3-1-4
! DANGER
Battery acid. Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
A289240
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1/3
Note operating instructions.

! CAUTION
Damaged or spent batteries and any residue from fires
A289270
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12
! WARNING
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8
8710-1

102
MAINTENANCE
BATTERY
(continued)
! WARNING Checking the Electrolyte Level

Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery away Maintenance free batteries used in normal temperate
from sparks and flames. climate applications should not need topping up.
However, in certain conditions (such as prolonged
Battery electrolyte contains sulphuric acid. It can burn you operation at tropical temperatures or if the alternator
if it touches your skin or eyes. Wear goggles. Handle the overcharges) the electrolyte level should be checked as
battery carefully to prevent spillage. Keep metallic items described below.
(watches, rings, zips etc) away from the battery terminals.
Such items could short the terminals and burn you. ! WARNING
Keep metal watch straps, and any metal fasteners on
Set all switches in the cab to OFF before disconnecting your clothes, clear of the positive (+) battery terminal.
and connecting the battery. When disconnecting the Such items can short between the terminal and nearby
battery, take off the ground (-) lead first. metal work. If this happens you can get burned.
5-2-2-4
When reconnecting, fit the positive (+) lead first.
1 Park the machine on firm level ground, engage the
Re-charge the battery away from the machine, in a well parking brake and set the transmission to neutral.
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have 2 Remove battery cell covers. Look at the level in each
installed the battery in the machine, wait five minutes cell. The electrolyte should be 6 mm (1/4 in) above
before connecting it up. the plates. Top up if necessary with distilled water or
de-ionised water.
First Aid - Electrolyte
! WARNING
Do the following if electrolyte:
Do not top the battery up with acid. The electrolyte
could boil out and burn you.
GETS INTO YOUR EYES 2-3-4-6
Immediately flush with water for 15 minutes, always get

medical help.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns

with a sterile dressing then get medical help.
5-3-4-3/1
S089660
8710-1

103
MAINTENANCE 103
ELECTRICAL SYSTEM
(continued)
Fuses D1 EMS (Ignition Feed) 3

D2 ZF Computer (Ignition Feed) 7.5
The electrical circuits are protected by fuses. The fuses D3 CCTV (Option) 5
are located in a fuse box to the rear of the side console. If D4 Blank -
a fuse ruptures, find out why and rectify the fault before D5 ESOS and Cold Start Advance 5
fitting a new one. D6 Reverse Lights and Alarm 5
D7 In-cab 24/12 Volt Converter (Option) 10
! CAUTION D8 Blank -
Fuses D9 Brake Lights 7.5
Always replace fuses with ones of correct ampere
D10 Float, Lift and Shovel Reset and 4th Spool 7.5
rating to avoid electrical system damage.
8-3-3-5
Fuse Circuit Fuse Rating

No. (Amps)
10 9 8 7 6 5 4 3 2 1
A1 Rear Work Lights 10 3 2 1 A 13
A2 Road Lights 15
A3 Front Work Lights 20 6 5 4 B 14
A4 Dipped Beam 10
A5 Main Beam 10
9 8 7 C 15
A6 Rear Fog Lights 5
A7 Grid Heater Relay 3
A8 Thermostart 30 12 11 10 D
A9 Dump Relay 3
A10 Ignition Relays 3
X Y
B1 Right Side/Tail Lights and Switch Illumination 3
A336170
B2 Left Side/Tail Lights and No. Plate Lights 3
B3 12 Volt Trailer Electrics (Option) 10
B4 EMS (Battery Feed) 3
B5 ZF Computer (Battery Feed) 7.5
B6 Hazard Warning 10
B7 Beacon and Interior Light 7.5
B8 Radio (24 Volt) 10
B9 Headlight Flash 15
B10 Side Lights 5
C1 Starter Relay Solenoid 3

C2 Cigar Lighter (24 Volt) See Note 10
C3 Blank -
C4 Rear Wash/Wipe 7.5
C5 Front Wash/Wipe and Horn 10
C6 Heated Seat/Mirrors and Air Suspension Seat
(Option) 10
C7 Air Conditioning (Option) 5
C8 Heater Blower 15
C9 Direction Indicators 5
C10 Heated Rear Screen 15
Note: Not fitted if in-cab 24/12 Volt converter fitted.
8710-1

104
MAINTENANCE 104
ELECTRICAL SYSTEM
Primary Fuses Relays

The primary fuses are located in a fuse box attached to 1 Heated Rear Screen
the battery positive terminal. If a fuse ruptures, find out 2 Ignition 2
why and rectify the fault before fitting a new one. 3 Flasher
4 Front Work Lights
Fuse Circuits Fuse Rating 5 Lights
6 Reverse Alarm/Lights
No. (Amps)
7 Dump
PF1 40 8 Air Conditioning
Front Work Lights 9 Blank
Rear Work Lights 10 ESOS
Main Beam 11 Ignition 1
Dip Beam 12 Ignition 3
Fog Lights 13 Wash/Wipe Interval Timer
PF2 40 14 Start
RH Side/Tail Lights & Switch Illumination 15 Blank
LH Side/Tail Lights & No. Plate Lights
Headlight Flash
Radio (24 Volt)
Beacon & Interior Light
Hazard Warning Diagnostic Connectors
EMS (Battery Feed)
ZF Computer (Battery Feed) X ZF Transmission
12 Volt Trailer Electrics Y EMS
PF3 446 - 40
456 - 60
Starter Solenoid
ESOS Pull
Heater Blower
Air Conditioning
Direction Indicators
Heated Seat, Mirrors & Air suspension Seat
Heated Rear Screeen PF4 PF2
Ignition Relays
PF4 50
EMS (Ignition Feed) PF3 PF1
ZF Computer (Ignition Feed)
Rear Wash/Wipe
Front Wash/Wipe & Horn
A336180
Cigar Lighter (24 Volt)
ESOS & Cold Start Advance
Reverse Alarm/Lights 10 9 8 7 6 5 4 3 2 1
Headlight Flash 3 2 1 A 13
Brake Lights
Shovel and Arm Reset
CCTV 6 5 4 B 14
In-cab 24/12 Volt Converter
9 8 7 C 15
12 11 10 D
X Y
A336170
8710-1

105
MAINTENANCE 105
ELECTRICAL SYSTEM
(continued)
Bulbs
Bulb Rating
(Watts)
Headlights - main 75 W
Headlights - dip 70 W
Indicators 21 W
Indicator repeater 5W
Instruments 1.2 W
Work lights 70 W Halogen
Number plate light 5W
Tail lights 5W
Front side lights 4W
Interior lights 10 W
Stop lights 21 W
Beacon 70 W Halogen
Rear fog 21 W
Warning lights 1.2 W
Master Warning Light 5W
WINDSCREEN WASHER
To gain access to the washer bottle A, open the left side

engine cover.
Fill the windscreen washer bottle with a suitable liquid.

The liquid should contain a de-icing fluid to prevent it
freezing. Do not use engine coolant antifreeze.
On completion, close the engine cover.
397050
8710-1

106
MAINTENANCE 106
TYRES AND WHEELS
Inflating the Tyres Checking the Wheelnut Torques

! WARNING On new machines, and whenever a wheel has been
removed, check the wheel nut torques every 2 hours until
Tyres and Rims
they stay correct.
Over-inflated or over-heated tyres can explode. Follow
the instructions in this handbook for inflating the tyres.
The correct torques are shown below.
Do not weld or cut rims. Get a tyre/wheel specialist to
do any repair work.
INT-3-2-6 Nm lbf ft
600 443
These instructions are for adding air to a tyre which is

already inflated. If the tyre has lost all its air pressure, call ! WARNING
in a qualified tyre mechanic. The tyre mechanic should
If, for whatever reason, a wheel stud is renewed, all
use a tyre inflation cage and the correct equipment to do
the studs for that wheel must be changed as a set,
the job.
since the remaining studs may have been damaged.
2-3-2-8
1 Before you add air to the tyre, make sure it is
correctly fitted on the machine or installed in a tyre
inflation cage.
2 Use only an air supply system which includes a

pressure regulator. Set the regulator no higher than
1.38 bar (20 lbf in2) above the recommended tyre
pressure.
Use an air hose fitted with a self-locking air chuck

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

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

over-inflate.
A089570
8710-1

107
MAINTENANCE 107
FLUIDS, CAPACITIES AND LUBRICANTS
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).
Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100
hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB
10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to
the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.
ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION
Engine Oil
-10°C to 50°C § 18.9 litres (4.2 UK gal) JCB Extreme Performance Engine Oil ACEA E3/B3/A3
15W/40 API CH-4/A3
Gearbox †34.0 litres (7.5 UK gal) JCB HP Universal ATF ZF TE-ML 09, 11, 12, 14
Axles 446 Front/456ZX Front & Rear/456HT Rear

51.0 litres (11.2 UK gal) JCB LS Gear Oil API GL4, MIL-L-2105B ††
446 Rear
456HT Front
Hydraulic System 215 litres (47.3 UK gal) JCB HP32 Hydraulic Fluid ISO VG32
Cooling System 40 litres (8.8 UK gal) Four Seasons Anti-freeze ASTM D3306, BS6580
& Summer Coolant/Water
(see Coolant mixtures)
Fuel System 370 litres (81.4 UK gal) Diesel Oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D.
Grease Points JCB HP Grease Lithium based
Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and
watch the level indicator.
Note: If JCB Special MPL Grease is used, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals.
† The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
†† Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
§ If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed at 250 hours.
Note: Biodegradable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradable Multigrade Hydraulic Fluid.
For further information, contact Wheeled Loader Technical Service.
8710-2

108
MAINTENANCE 108
FIRE EXTINGUISHER
Checking the Fire Extinguisher

Check the fire extinguisher for damage, security and signs
of leakage.
Check that the gauge indicates that the extinguisher is

charged ie. the needle is in the GREEN segment.
Note: If the needle is in or very near the RED segment at

either end of the gauge, the extinguisher must be serviced
or replaced.
Make sure that the safety pin is fitted and secure.
The extinguisher should be serviced every 12 months by

suitably qualified personnel.
OBTAINING REPLACEMENT PARTS
We recommend you fit only JCB Genuine Parts. A ! WARNING

Wheeled Loader Parts Book will help you identify parts
Some parts of your machine have Warning Decals
and order them from your JCB distributor.
attached. Before you fit a replacement part, make
sure it has its warning decal, fixed in its correct
Your distributor will need to know the exact model, build
position. See Safety Decals in INTRODUCTION section.
and serial number of your machine. The machine's serial
Contact your distributor if the decal is missing.
number is stamped on a data plate on the left hand side of 2-3-5-2/1
the front chassis. See Identifying Your Machine in
INTRODUCTION section.
The data plate also shows the serial numbers of the

engine, transmission and the axles. Remember that if any
of these units have been changed, the serial number on
the data plate may be wrong. Check on the unit itself.
8710-1

131
OPTIONAL ATTACHMENTS 131
INTRODUCTION
This part of the handbook provides information on the ! CAUTION

optional attachments which are available for the JCB
If you have an attachment which is not covered in this
Wheeled Loader.
handbook, don't install it, use it or remove it until you
have obtained, read and understood the pertinent
INTRODUCTION information. Install attachments only on the machines
for which they were designed.
A wide range of optional attachments is available to 5-5-1-1
increase the versatility of your machine. Only JCB
approved attachments are recommended for use with Should you consider fitting an attachment from an
your machine. Consult your JCB Distributor for the full list alternative manufacturer, we strongly recommend that you
of approved attachments available. first seek the expert advice of your JCB Distributor to
ascertain the compatibility of the attachment with the
JCB attachments are designed and manufactured machine.
specifically to suit the machine's hydraulic system,
mounting arrangements and safe load requirements.
Attachments which are not designed for use with this
machine may cause damage and create safety hazards for
which JCB cannot be held responsible. In addition the
machine's warranty, “CE” and any other legislative
compliance may be affected by the use of non JCB
approved attachments.
2-4-1-13/2
For other JCB attachments this information is provided in

the form of a specific handbook supplied with each
attachment. General installation and removal procedures
for these attachments are, however, included here.
Before installing, using or removing any optional

attachment, make sure you read and understand the
information provided. If there is anything you do not
understand, ask your JCB distributor.
The 446 Wheeled Loaders are fitted with direct mount

attachments as listed below.
2.7 m3 General Purpose Shovel

The 456 Wheeled Loaders are fitted with direct mount

attachments as listed below.

3.1 m3 Penetration Shovel
8710-1


151
SPECIFICATIONS 151
LIFTING (CRANING) REGULATIONS AND SAFE WORKING LOADS
Lifting Regulations Safe Working Loads

The Factories Act Construction (Lifting Operations) ! WARNING
Regulations 1961 defines 'Loaders' as 'Lifting Appliances'.
The safe working load indicated on lifting accessories
As such, the JCB Wheeled Loader is subject to these
such as chains etc. is not the safe working load of the
regulations both when using the machine as a loader, and
machine. Consult your handbook for the safe working
specifically when using the machine as a crane.
load of the machine.
4-5-1-1
The owner and/or operator must make sure that he fully
understands the laws and regulations concerning the use The Safe Working Load is expressed as the full turn tip
of the JCB Wheeled Loader as a loader and as a crane. load in the Working Capacity section.
Consult your JCB Distributor for further information.
! WARNING
If your machine has not been fitted with an approved
Lifting Equipment
lifting point such as a hook or shackle then it must not be
You can be injured if you use faulty lifting equipment.
used as a crane. Use the machine for loading purposes
Make sure that lifting equipment is in good condition.
only.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
Your machine may be used as a crane if it has been fitted
lifting equipment is strong enough for the job.
with an approved lifting point such as a hook or shackle, if INT-1-3-7
it has been tested, plated and certified for its safe working
load, and if all other regulation requirements have been
met (consult your JCB Distributor). Loader Unit
In all cases the maximum load to be lifted by the loader
unit when used as a crane is 1000 kg (1 tonne, 2205 lb).
TYRE PRESSURES
Note: The maximum pressure embossed on the tyre may differ from the pressure stated below. Inflate to pressures below,
these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Organisation (ETRTO) standards
to satisfy machine stability performance.
FRONT REAR
Model Size Ply Bar lbf/in2 Bar lbf/in2
446 20.5 - 25 16 4.25 62 2.25 33
446 23.5 - 25 16 3.5 51 2.00 29
446 23.5 R25 - 3.5 51 2.00 29
446 555/70R25 - 4.75 69 2.25 33
456 23.5 - 25 16 3.5 51 2.00 29
456 23.5 R25 - 3.5 51 2.00 29
456 625/70R25 - 3.75 54 2.00 29
Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre
pressures.
8710-1

152
SPECIFICATIONS 152
WORKING CAPACITY
Shovel Type Shovel Size Shovel Weight Full turn Tip Load
446 (20.5 Tyres)
m3 Kg (lb) Kg (lb)
General Purpose 2.7 1368(3016) 9853(21722)
General Purpose 3.0 1644 (3624) 9771(21541)
General Purpose 3.3 1717 (3785) 9651(21277)
446 (23.5 Tyres)

m3 Kg (lb) Kg (lb)
General Purpose 2.7 1368(3016) 10279(22661)
General Purpose 3.0 1644 (3624) 10196(22478)
General Purpose 3.3 1717 (3785) 10074(22209)
456
m3 Kg (lb) Kg (lb)
General Purpose 3.0 1644 (3624) 11600 (25573)
General Purpose 3.3 1717 (3785) 11527 (25412)
General Purpose 3.5 1760 (3880) 11484 (25318)
Penetration* 3.1 1652 (3642) 11592 (25556)
* with tipped teeth.
Note: This is not a table for Safe Working Loads for craning.
All rated capacities are based on the criteria of the machine being level and on a firm supporting ground. When the machine
is operated in conditions that deviate from these criteria (e.g. on soft or uneven ground, on a slope or when subject to side
loads), these conditions shall be taken into account by the operator.
8710-1

153
SPECIFICATIONS 153
STATIC DIMENSIONS
446 456ZX
mm ft in mm ft in
A Overall length (including standard shovel) 7908 26 2 7908 26 2
B Wheelbase 3300 10 10 3300 10 10
C Centre of Gravity (No attachment fitted) 2200 7 3 2200 7 3
D Minimum ground clearance 409 1 4 450 1 6
E Height over cab 3329 10 11 3370 11 1
F Width (Over tyres- without bulge) 2702 8 10 2702 8 10

(Maximum - Shovel Toeplate) 2800 9 2 2800 9 2
G Pin height (maximum) 4066 13 4 4107 13 6
H Maximum height 5530 18 1 5571 18 3
J Dump height 2909 9 6 2950 9 8
K Axle oscillation 12.5° 12.5°
L Dump angle at full height 45° 45°
M Roll back angle at full height 67° 67°
Articulation angle 40° 40°
Kg lb Kg lb
Unladen Weight 16710 36839 18600 41005
Note: Dimensions based on a 446 machine equipped with the standard 2.7 m3 shovel and 20.5R25 L3 tyres.
Dimensions based on a 456ZX machine equipped with the standard 3.0 m3 shovel and 23.5R25 L3 tyres.
K
D
C F
A B
L
H
G
J
397230
8710-2

154
SPECIFICATIONS 154
STATIC DIMENSIONS
(continued)
456HT
mm ft in
A Overall length (including standard shovel) 8540 28 0
B Wheelbase 3300 10 10
C Centre of Gravity (No attachment fitted) 2250 7 5
D Minimum ground clearance 450 1 6
E Height over cab 3370 11 1
F Width (Over tyres- without bulge) 2700 8 10
G Pin height (maximum) 4300 14 1
H Maximum height 5990 19 8
J Dump height 3013 9 11
K Axle oscillation 12.5°
L Dump angle at full height 45°
M Roll back angle at full height 57°
Articulation angle 40°
Kg lb
Unladen Weight 20101 44314
Note: Dimensions based on a 456HT machine equipped with the standard 3.0 m3 shovel and 23.5R25 L3 tyres.
E
1
K D
F C
B
A
HL
G
J
417130
8710-1

155
SPECIFICATIONS 155
NOISE AND VIBRATION DATA
446 456ZX 456HT
The noise data below applies to CE marked machines.
NOISE
1 Noise Level at Operator's Ear (LpA) 73 77 77
2 External Noise Level - Guaranteed Sound Power Level (LwA) 108 109 109
VIBRATION
3 Weighted rms acceleration : Whole Body (m/s2) 1.04 1.04 1.04
4 Weighted rms acceleration : Hand/Arm (m/s2) < 2.5 < 2.5 < 2.5
Item 1 above determined in accordance with dynamic test conditions defined in ISO 6396.
Item 2 above determined in accordance with dynamic test conditions defined in 2000/14/EC (Annex 5, 6).
Item 3 above is an "Average Equivalent Value" determined from measurement on machines performing typical duties
detailed below, with values weighted in accordance with ISO 2631.
Item 4 above measured at the steering control device when the machine is travelling over an irregular "Quarry floor" surface,
with values weighted in accordance with ISO 2631.
The Vibration values are determined from measurements in three perpendicular planes.
Values determined with standard shovel fitted.
Typical Duties for Wheeled Loading Shovel machine: Loading cycles

Roading (Tarmac)
Roading (Rough Terrain)
8710-2


SERVICE RECORD SHEET
Distributor Preparation 4500 Hr./27 Month

/P.D.I.
Date ...............................
Date ............................... Hour Reading ................
First 100 Hr./2 Weeks 5000 Hr./30 Month
Date ............................... Date ...............................

Hour Reading ................ Hour Reading ................
500 Hr./3Month 5500 Hr./33 Month
Date ............................... Date ...............................

1000 Hr./6 Month 6000 Hr./36 Month

Annual Insurance Inspection
Date ............................... Date ...............................
Date ............................... Date ...............................

Date ............................... Date ...............................
Date ............................... Date ...............................
3000 Hr./18 Month 8000 Hr./48Month

Date ............................... Date ...............................
Date ............................... Date ...............................

Date ............................... Date ...............................
Issue 2 Jul. 94
8710-1


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

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

ALPHA • DOT SECURITY SYSTEM - YES/NO
9 Please send details of:

"JCB Assetcare Machinery Protection Plan"



*9801/8710*
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446,456 Operators Manual

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Operator Waterloo Park

Handbook Produced by the Technical

446 456ZX 456HT

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

Purchased from www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

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

JCB PLANTGUARD is a comprehensive package available to help you safeguard

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

Purchased from www.WorkshopManuals.co.uk

INTRODUCTION Display Panel

Entering/Leaving the Cab ................................... 22 Starting the Engine ........................................... 45

Door and Windows Jump-Starting the Engine . ............................... 46

Seat Belt Getting the Machine Moving

Cab Layout ........................................................ 26 Testing the Parking Brake ................................ 51

Loader Control Lock ........................................... 34 Moving a Disabled Machine ............................ 55

Transporting the Machine .................................. 56

Purchased from www.WorkshopManuals.co.uk

Height Restriction System ................................. 59 Engine Air Filter

Service Requirements Engine Drive Belt ................................................. 90

ROPS/FOPS Structure Transmission

Checking for Damage ....................................... 82 Electrical System

Purchased from www.WorkshopManuals.co.uk

Tyres and Wheels

Fluids, Capacities and Lubricants ................... 107

Obtaining Replacement Parts .......................... 108

Introduction ....................................................... 131

Lifting (Craning) Regulations and Safe Working Loads

Tyre Pressures .................................................... 151

Working Capacity ................................................ 152

Static Dimensions ............................................... 153

Noise and Vibration Data ................................. 154

SERVICE RECORD SHEET ............... At back of book

Purchased from www.WorkshopManuals.co.uk

ABOUT THIS HANDBOOK

Machine Model and Serial Number

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

The manufacturer's policy is one of continuous

Left Side, Right Side

Purchased from www.WorkshopManuals.co.uk

THE JCB WHEELED LOADER

1 Engine Oil Level Dipstick

Purchased from www.WorkshopManuals.co.uk

SAFETY FIRST - YOURS AND OTHER PEOPLES

All construction and agricultural equipment can be ! WARNING

Purchased from www.WorkshopManuals.co.uk

SAFETY - CHECK LIST

Purchased from www.WorkshopManuals.co.uk

SAFETY - CHECK LIST

Purchased from www.WorkshopManuals.co.uk

SAFETY - CHECK LIST

! WARNING New fluoroelastomeric components at ambient

Purchased from www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

IDENTIFYING YOUR MACHINE

If the engine or transmission is replaced by a new one, the

The engine serial number is stamped on a plate W on the

The axle serial number is stamped on a plate mounted on

The transmission serial number is stamped on a plate X

Purchased from www.WorkshopManuals.co.uk

Before starting the machine, sit in the driver's seat and

BEFORE ENTERING THE CAB

d Inspect the windows for cracks and damage.