JCB 1CX Operators Manual

Operator Handbook

JCB 1CXFrom serial number 751600 to 752999

and from 806000 Onwards

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

Publication Number 9801/4230 April 2002 Issue 14

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

www.classicmachinery.net

SAFETY NOTICES

! WARNINGStudy This Handbook Before Starting The Machine

You must understand and follow the instructions in this handbook. You must observeall relevant laws and regulations. If you are unsure about anything, ask your JCBdistributor or employer. Do not guess, you or others could be killed or seriouslyinjured.INT-1-1-1

! CAUTIONDo not fit an attachment to this machine which is not JCB approved. Consult yourJCB distributor before fitting any non approved attachment.8-4-1-6

4230-1

In this handbook and on the machine there are safety notices. Each notice startswith a signal word. The meanings of the signal words are given below.

! DANGERDenotes an extreme hazard exists. If proper precautions are not taken, it ishighly probable that the operator (or others) could be killed or seriouslyinjured.INT-1-2-1

! WARNINGDenotes a hazard exists. If proper precautions are not taken, the operator(or others) could be killed or seriously injured.INT-1-2-2

! CAUTIONDenotes a reminder of safety practices. Failure to follow these safetypractices could result in injury to the operator (or others) and possibledamage to the machine.INT-1-2-3

MACHINE SECURITY

Vandalism and theft of unattended machines is an ever increasing problem andJCB is doing everything possible to help combat this.

JCB PLANTGUARD is a comprehensive package available to help you safeguardyour machine. It includes such devices as vandal proof covers, window etching,immobiliser, concealed serial number, battery isolator, Tracker security systemand much more.

Remember that the fitting of any one of these security devices will help tominimise not only the damage or loss of your machine but also subsequent lostproductivity. It could also result in reduced insurance premiums.

Your JCB Distributor or Dealer will be pleased to provide information on any ofthese sensible precautions. ACT NOW!INT-1-2-4




i iCONTENTS

INTRODUCTION Page

About this HandbookMachine Models ........................................................ 1Location of Handbook ............................................... 1Using this Handbook ................................................. 1Units of Measurement ............................................... 1Page Numbering ....................................................... 1Left Side, Right Side ................................................. 1Using the Machine .................................................... 1

The JCB 1CXMachine Description ................................................. 2

Safety First - Yours and Other People's ............... 3

Safety Check ListGeneral Safety .......................................................... 3Operating Safety ....................................................... 4Maintenance Safety .................................................. 5

Safety Decals .......................................................... 6

Identifying Your MachineMachine Identification Plate ...................................... 8Typical Vehicle Identification Number (VIN) ............... 8Unit Identification ...................................................... 8

JCB Immobiliser Option ......................................... 9

OPERATION

Introduction ............................................................ 21

Before Entering the Cab ........................................ 21

Entering/Leaving the Cab ....................................... 22Backhoe Control Lever Lock .................................... 23Leaving the Cab in an Emergency ........................... 23

Cab Light (Cab Machines only) .............................. 23

Door and Windows (Cab Machines only) ............. 24

Seat BeltFastening the Seat Belt ........................................... 25Releasing the Seat Belt ........................................... 25Checking Seat Belt Operation ................................. 25

Cab Layout ............................................................. 26

Heater Controls (Cab Machines only) ................... 28

Switches and InstrumentsSwitches .................................................................... 28Warning Indicators ................................................... 30Hourmeter ................................................................ 30

Page

Seat Controls ......................................................... 31

Loader ControlsLoader Arm/Shovel Control Lever .............................. 31Auxiliary Attachments Control Switches ..................... 32Auxiliary Attachments Detent Switch .......................... 32High-flow Hydraulic Switch ......................................... 32Float Control Switch ................................................... 32

Stabiliser Controls ................................................... 33

Backhoe Controls (JCB X Pattern)JCB X Pattern .......................................................... 34Boom and Slew Movements .................................... 35Dipper and Bucket Movements ............................... 36

Backhoe Controls (JCB + Pattern)JCB + Pattern .......................................................... 37Boom and Slew Movements .................................... 38Dipper and Bucket Movements ............................... 39

Backhoe Controls (ISO Pattern)ISO Pattern ............................................................. 40Dipper and Slew Movements .................................. 41Boom and Bucket Movements ................................ 42

Hydraclamps ......................................................... 43

Foot Operated Pedal ............................................ 43

Before Starting the Engine .................................. 44

Starting the Engine ............................................... 45

Jump-Starting the Engine .................................... 46

Preparing the Machine for TravelTravelling on Site .................................................... 47Travelling on the Road ............................................. 48Travelling on the Road (UK only) .............................. 48

Boom/Slew LockEngage the Boom/Slew Lock .................................... 50Release the Boom/Slew Lock ................................... 50

Rotating Beacon .................................................... 51

Testing the Parking Brake ..................................... 51

Getting the Machine MovingDrive Control Lever .................................................... 52Operating Procedures ............................................... 52Getting Moving ......................................................... 53

Stopping and Parking the Machine ...................... 53

Using the Attachments and Site Safety ............... 54

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ii iiCONTENTS

OPERATION cont'd Page

Loader QuickhitchEngaging the Shovel/Attachments ........................... 56Disengaging the Shovel/Attachments ...................... 57

Working with the LoaderFilling the Shovel ...................................................... 58Loading a Truck ........................................................ 58Scraping and Cutting ................................................ 58

Working with the BackhoeRemoving a Bucket .................................................. 59Fitting a Bucket ........................................................ 59Preparing to Use the Backhoe ................................. 60Digging ..................................................................... 60Moving the Machine While Digging .......................... 61Digging Near Walls .................................................. 61Digging on Slopes ................................................... 61

Sideshifting the Backhoe ...................................... 62

Operating in Low Temperatures ........................... 63

Operating in High Temperatures .......................... 63

Transporting the MachineUsing a Truck .......................................................... 64Using a Trailer ......................................................... 64Transportation Safety .............................................. 65

Moving a Disabled Machine ................................. 65

Emergency Lower Procedure .............................. 66

MAINTENANCE

Lubricants - Health and SafetyHygiene .................................................................... 71Storage .................................................................... 71Waste Disposal ........................................................ 71Handling ................................................................... 71First Aid - Oil ............................................................ 71Spillage .................................................................... 71Fires ......................................................................... 71

Service Requirements ........................................... 72

Service SchedulesEvery 10 Operating Hours or Weekly(first 50 operating hrs. only) ...................................... 73Every 10 Operating Hours or Daily .......................... 73After the First 50 Operating Hours only ................... 73Every 50 Operating Hours or Weekly ...................... 73Every 100 Operating Hours or 2 Weekly ................. 74Every 250 Operating Hours or Monthly ................... 74Every 500 Operating Hours or 6 Monthly ................ 74Every 1000 Operating Hours or Yearly .................... 74Every 2000 Operating Hours or 2 Yearly ................. 74

Page

Cleaning the Machine ............................................ 75

Checking for Damage ............................................ 75

ROPS/FOPS StructureChecking the ROPS/FOPS Structure ....................... 75

Loader Arm Safety StrutInstalling the Safety Strut ......................................... 76Removing the Safety Strut ....................................... 76

Engine Compartment AccessOpening and closing the Bonnet .............................. 77Removing and Fitting a Side Panel .......................... 77

Removing Floor Plates ......................................... 77

Seat BeltChecking Seat Belt Condition and Security ............. 78

Greasing (10 Hours)Quickhitch Pivot Points ............................................ 78Loader Arm Pivot Points .......................................... 79Backhoe ................................................................... 80

LubricationOiling Control Levers ............................................... 81Oiling Door Hinges (Cabbed Machines) .................. 81Checking Slew Oil Level .......................................... 81

Engine Air FilterChanging the Elements ............................................ 82

Engine Oil and FilterChecking the Oil Level ............................................ 83Changing the Oil and Filter ..................................... 83

Engine Cooling System Coolant Mixtures ..................................................... 85Checking the Coolant Level .................................... 85Changing the Coolant ............................................. 86Cleaning the Coolant Radiator ................................ 86

Engine Alternator BeltChecking the Alternator Belt Tension ..................... 87Adjusting the Alternator Belt ................................... 87

Drive Chain LubricationChecking the Oil Levels .......................................... 88

Fuel SystemTypes of Fuel ........................................................... 89Fuel Standards ........................................................ 89Low Temperature Fuels ........................................... 89Petrol ....................................................................... 89Advice ...................................................................... 89Filling the Tank ........................................................ 89Draining the Fuel Filter .............................................. 90Changing the Fuel Filter Element ............................. 90

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http://www.workshopmanuals.co.uk


iii iiiCONTENTS

MAINTENANCE cont'd Page

Hydraulic SystemChecking the Fluid Level .......................................... 91Changing the Filter ................................................... 91

BatterySafety ....................................................................... 92Warning Symbols ..................................................... 93Checking the Electrolyte Level ................................. 93

Electrical SystemFuses ....................................................................... 94Relays ...................................................................... 94Light Bulbs ............................................................... 94

Tyres and WheelsInflating the Tyres .................................................... 95Renewing Segments of Optional Non-Inflatable Tyres 95Checking the Wheel Bolt Torques ........................... 95

Windscreen Washer .............................................. 96

Fluids, Capacities and Lubricants ....................... 97

Obtaining Replacement Parts .............................. 97

Storage ..................................................................... 98

OPTIONAL ATTACHMENTS Page

Introduction .......................................................... 111

Quick Release Couplings .................................... 112

Connecting/Disconnecting Hydraulic Hoses ........ 112

ShovelsGeneral Purpose and Light Duty Shovels ................. 114

6-in-1 Shovel ............................................................ 115

Pallet Forks .............................................................. 117

Manure/Silage Fork with Top Grab ........................ 118

Attachment Frame ................................................... 120

Backhoe Quickhitch ............................................... 121Installing the Quickhitch ........................................... 121Removing the Quickhitch ......................................... 121Maintenance ............................................................ 121Installing Backhoe Quickhitch Attachments ............. 122Removing Backhoe Quickhitch Attachments ........... 124

SPECIFICATION

Static Dimensions and Specifications .................. 131

Optional Attachments ........................................... 133

Noise and Vibration Data ..................................... 134

Tipping Loads ....................................................... 134

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1 1INTRODUCTION

ABOUT THIS HANDBOOK

Machine Models

This handbook provides information for the JCB 1CXmachine from serial number 751600 to 752999 and from806000 onwards.

Location of Handbook

The handbook is located in a pocket on the seat back, asat A. The handbook should always be returned to itscorrect stowage.

Using this Handbook

The illustrations in this handbook are for guidance only.Where the machines differ, the text and/or the illustrationwill specify.

This handbook is arranged to give you a goodunderstanding of the machine and its safe operation. It alsocontains maintenance information and specification data.Read this handbook from front to back before using themachine for the first time. Particular attention must be givento all the safety aspects of operating and maintaining themachine.

General warnings in this chapter are repeated throughoutthe book, as well as specific warnings. Read all the safetystatements regularly, so you do not forget them. Rememberthat the best operators are the safest operators.

Finally, treat this handbook as part of the machine. Keep itclean and in good condition. Do not operate the machinewithout a handbook in the cab. If there is anything you arenot sure about, ask your JCB distributor or employer. Donot guess, you or others could be killed or seriously injured.

The manufacturer's policy is one of continuousimprovement. The right to change the specification of themachine without notice is reserved. No responsibility will beaccepted for discrepancies which may occur betweenspecif ications of the machine and the descriptionscontained in this publication.INT-1-2-5/1

Units of Measurement

In this handbook, the S.I. system of units is used. Forexample, liquid capacities are given in litres. The Imperialunits follow in parenthesis () eg 28 litres (6 gal).

Page Numbering

The page numbering system in this handbook is notcontinuous. There is a gap between sections. This allowsfor the insertion of new pages in later issues of thehandbook.

Left Side, Right Side

In this handbook, unless otherwise specified in the text,'left' and 'right' mean your left and right when you areseated in the machine facing the loader end as shown atB. The only exception to this is in 'Backhoe Controls' inOPERATION section. This is because you will be facingthe backhoe (rear) end of the machine, as shown at C,when operating these controls and your left and right arereversed.

Using the Machine

To use the 1CX efficiently and safely you must know themachine and have the skill to use it. This handbookinstructs you on the machine, its controls and its safeoperation. It is not a training manual on the art of loadingand excavating. If you are a new operator, get yourselftrained in the skills of using a 1CX before trying to workwith it. If you do not, you will not do your job well, and youwill be a danger to yourself and others.

4230-2

S202361 S202340

B

C

A






2 2INTRODUCTION

THE JCB 1CX

Machine Description

The 1CX is a self propelled wheeled skid steer machine with a main structural support designed to carry both a front mountedbucket loading mechanism and a rear mounted backhoe. When used in the backhoe mode, the machine normally digs belowground level with bucket motion towards the machine; the backhoe lifts, swings and discharges material while the machine isstationary. When used in the loader mode, the machine loads or excavates through forward motion of the machine, and lifts,transports and discharges material.

4230-1

S202351

S202361

FRONT WORK LIGHT

LOADER ARM

DRIVE CONTROLS

BEACON

LOADER SHOVEL

REAR WORK LIGHT

LOADER CONTROLS

EXCAVATOR CONTROLS

DIPPER

BUCKET






3 3INTRODUCTION

SAFETY FIRST - YOURS AND OTHER PEOPLE'S

All construction and agricultural equipment can behazardous. When a 1CX is correctly operated and properlymaintained, it is a safe machine to work with. But when it iscarelessly operated or poorly maintained it can become adanger to you (the operator) and others.

In this handbook and on the machine you will find warningmessages. Read and understand them. They tell you ofpotential hazards and how to avoid them. If you do not fullyunderstand the warning messages, ask your employer orJCB distributor to explain them.

But safety is not just a matter of responding to thewarnings. All the time you are working on or with themachine you must be thinking what hazards there might beand how to avoid them.

General Safety

! HandbookYou and others can be injured if you operate ormaintain the machine without first studying thishandbook. Read the safety instructions beforeoperating the machine. If you do not understandanything, ask your employer or JCB distributor toexplain it. Keep this handbook clean and in goodcondition. Do not operate the machine without ahandbook in the cab, or if there is anything on themachine you do not understand.INT-1-3-2

! RegulationsObey all laws, work site and local regulations whichaffect you and your machine.INT-1-3-3

! DecalsYou can be injured if you do not obey the decal safetyinstructions. Keep decals clean. Replace unreadable ormissing decals with new ones before operating themachine. Make sure replacement parts include warningdecals where necessary.INT-1-3-4

! Care and AlertnessAll the time you are working with or on the machine,take care and stay alert. Always be careful. Always bealert for hazards.INT-1-3-5

! Raised AttachmentsRaised attachments can fall and injure you. Do notwalk or work under raised attachments unless they aresafely blocked.INT-1-3-8

Do not work with the machine until you are sure that youcan control it.

Do not start any job until you are sure that you and thosearound you will be safe.

If you are unsure of anything, about the machine or the job,ask someone who knows. Do not assume anything.

RememberBE CAREFUL

BE ALERTBE SAFE

INT-1-3-1/1

! ClothingYou can be injured if you do not wear the properclothing. Loose clothing can get caught in themachinery. Wear protective clothing to suit the job.Examples of protective clothing are: a hard hat, safetyshoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened.Do not wear a necktie or scarf. Keep long hairrestrained.INT-1-3-6

! Lifting EquipmentYou can be injured if you use faulty lifting equipment.Make sure that lifting equipment is in good condition.Make sure that lifting tackle complies with all localregulations and is suitable for the job. Make sure thatlifting equipment is strong enough for the job.INT-1-3-7

! Alcohol and DrugsIt is extremely dangerous to operate machinery whenunder the influence of alcohol or drugs. Do notconsume alcoholic drinks or take drugs before or whilstoperating the machine or attachments. Be aware ofmedicines which can cause drowsiness.INT-1-3-9

! Machine ModificationsThis machine is manufactured in compliance withlegislative and other requirements. It should not bealtered in any way which could affect or invalidate anyof these requirements. For advice consult your JCBDistributor.

Reference should also be made to OptionalAttachments section where appropriate.INT-1-3-10

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SAFETY CHECK LIST






4 4INTRODUCTION

SAFETY CHECK LIST(continued)

Operating Safety

! PracticeYou or others can be killed or seriously injured if youdo unfamiliar operations without first practising them.Practise away from the work site on a clear area. Keepother people away. Do not perform new operationsuntil you are sure you can do them safely.INT-2-1-1

! Machine ConditionA defective machine can injure you or others. Do notoperate a machine which is defective or has missingparts. Make sure the maintenance procedures in thishandbook are completed before using the machine.INT-2-1-2

! ControlsYou or others can be killed or seriously injured if youoperate the control levers from outside the cab.Operate the controls levers only when you arecorrectly seated inside the cab.INT-2-1-3

! Machine LimitsOperating the machine beyond its design limits candamage the machine, it can also be dangerous. Do notoperate the machine outside its limits. Do not try toupgrade the machine performance with unapprovedmodifications.INT-2-1-4

! RolloverShould the machine start to roll over, you can becrushed if you try to leave the cab. If the machinestarts to roll over, DO NOT TRY TO JUMP FROM THECAB. STAY IN THE CAB, WITH YOUR SEAT BELTFASTENED.INT-2-1-12

! ROPS/FOPS StructureThe machine is fitted with a Roll Over ProtectionStructure (ROPS) and a Falling Objects ProtectionStructure (FOPS). You could be killed or seriouslyinjured if you operate the machine with a damaged ormissing ROPS/FOPS. If the ROPS/FOPS has been inan accident, do not use the machine until the structurehas been renewed. Modifications and repairs that arenot approved by the manufacturer may be dangerousand will invalidate the ROPS/FOPS certification.INT-2-1-9/3

! Seat BeltsThe ROPS/FOPS cab is designed to give youprotection in an accident. If you do not wear your seatbelt, you could be thrown around inside the cab orthrown out of the machine and crushed. You mustwear a seat belt when using the machine. Fasten theseat belt before starting the engine.2-2-1-9

! Cold StartingDo not use ether or other starting fluids to assist coldstarting. Using these fluids may result in an explosioncausing possible injury and/or damage to the engine. 3-2-1-9

! Exhaust GasesBreathing the machine exhaust gases can harm andpossibly kill you. Do not operate the machine in closedspaces without making sure there is good ventilation. Ifpossible, fit an exhaust extension. If you begin to feeldrowsy, stop the machine at once. Get out of the cabinto fresh air.INT-2-1-10

! Hazardous AtmospheresThis machine is designed for use in normal out dooratmospheric conditions. It should not be used in anenclosed area without adequate ventilation. Do not usethe machine in a potentially explosive atmosphere, i.e.combustible vapours, gas or dust, without f irstconsulting your JCB Distributor.INT-2-1-14

! VisibilityAccidents can be caused by working in poor visibility.Keep windows clean and use your lights to improvevisibility. Do not operate the machine if you cannot seeproperly.INT-2-1-11

! PassengersPassengers in or on the machine can cause accidents.The JCB Skid Steer Loader is a one man machine. Donot carry passengers.INT-2-2-2

! Ramps and TrailersWater, mud, ice, grease and oil on ramps or trailerscan cause serious accidents. Make sure ramps andtrailers are clean before driving onto them. Useextreme caution when driving onto ramps and trailers.Always reverse up a ramp if unloaded, travel forwardsif loaded. Always reverse down a ramp if loaded, travelforwards if unloaded.3-1-1-3/1

! SparksExplosions and fire can be caused by sparks from theexhaust or the electrical system. Do not use themachine in closed areas where there is flammablematerial, vapour or dust.INT-2-2-10

! Safe Working LoadsOverloading the machine can damage it and make itunstable. Study the lifting and/or digging specificationsin this handbook before using the attachments.INT-2-2-11/1

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5 5INTRODUCTION


Maintenance Safety

! RepairsDo not try to do repairs or any other type ofmaintenance work you do not understand. Get aService Manual from your JCB distributor, or get thework done by a specialist engineer.INT-3-1-1

! Modifications and WeldingNon-approved modifications can cause injury anddamage. Parts of the machine are made from castiron; welds on cast iron can weaken the structure andbreak. Do not weld cast iron. Contact your JCBdistributor for advice before modifying the machine.INT-3-1-2/1

! Metal SplintersYou can be injured by flying metal splinters whendriving metal pins in or out. Use a soft faced hammeror drift to remove and fit metal pins. Always wearsafety glasses.INT-3-1-3

! CommunicationsBad communications can cause accidents. If two ormore people are working on the machine, make sureeach is aware of what the others are doing. Beforestarting the engine make sure the others are clear ofthe danger areas; examples of danger areas are: therotating blades and belt on the engine, theattachments and linkages, and anywhere beneath orbehind the machine. People can be killed or injured ifthese precautions are not taken.INT-3-1-5

! Soft GroundA machine can sink into soft ground. Never work undera machine on soft ground.INT-3-2-4

! Raised MachineNEVER position yourself or any part of your bodyunder a raised machine which is not properlysupported. If the machine moves unexpectedly youcould become trapped and suffer serious injury or bekilled.INT-3-3-7/1

! PetrolDo not use petrol in this machine. Do not mix petrolwith the diesel fuel; in storage tanks the petrol will riseto the top and form flammable vapours.INT-3-1-6

! Diesel FuelDiesel fuel is flammable; keep naked flames awayfrom the machine. Do not smoke while refuelling themachine or working on the engine. Do not refuel withthe engine running. There could be a fire or injury ifyou do not follow these precautions.INT-3-2-2

! OilOil is toxic. If you swallow any oil, do not inducevomiting, seek medical advice. Used engine oilcontains harmful contaminants which can cause skincancer. Do not handle used engine oil more thannecessary. Always use barrier cream or wear gloves toprevent skin contact. Wash skin contaminated with oilthoroughly in warm soapy water. Do not use petrol,diesel fuel or paraffin to clean your skin.INT-3-2-3

! Electrical CircuitsUnderstand the electrical circuit before connecting ordisconnecting an electrical component. A wrongconnection can cause injury and/or damage.INT-3-1-4

Do not disconnect the battery while the engine isrunning otherwise the electrical circuits may bedamaged.INT-3-1-14

Do not switch the battery isolator to OFF while theengine is running. Failure to comply may result indamage to the electrical circuits.4-2-1-7

! Arc WeldingBefore carrying out arc welding on the machine,disconnect the battery and alternator to protect thecircuits and components.

The battery must still be disconnected even if a batteryisolator is fitted.

Make sure that the welding earth return path is kept asshort as possible. This prevents high currents beinginduced in the machine chassis or wiring harnesses.

If the machine is equipped with amplifier drivers orelectronic control units (E.C.U.s) then disconnect thembefore welding. Failure to disconnect the amplifierdrivers or E.C.U.s could result in irreparable damageto the electronic components.INT-3-1-15/1

! FiresIf your machine is equipped with a fire extinguisher,make sure it is checked regularly. Keep it in theoperator's cab until you need to use it.

Do not use water to put out a machine fire, you couldspread an oil fire or get a shock from an electrical fire.Use carbon dioxide, dry chemical or foamextinguishers. Contact your nearest fire department asquickly as possible. Firefighters should use self-contained breathing apparatus.INT-3-2-7/1

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6 6INTRODUCTION


Maintenance Safety (continued)

! Hydraulic FluidFine jets of hydraulic fluid at high pressure canpenetrate the skin. Do not use your fingers to check forhydraulic fluid leaks. Do not put your face close tosuspected leaks. Hold a piece of cardboard close tosuspected leaks and then inspect the cardboard forsigns of hydraulic fluid. If hydraulic fluid penetratesyour skin, get medical help immediately.INT-3-1-10/1

! Hydraulic PressureHydraulic fluid at pressure can injure you. Make themachine safe before connecting or disconnecting quickrelease couplings; stop the engine then turn the starterswitch to IGN and operate the auxiliary attachmentcontrol switch a few times to vent residual hydraulicpressure in the attachment hoses.3-4-1-3

! RamsThe efficiency of the rams will be affected if they arenot kept free of solidified dirt. Clean dirt from aroundthe rams regularly. When leaving or parking themachine, close all rams if possible to reduce the risk ofweather corrosion.INT-3-2-10

! WARNINGDecals on the machine warn you of particular hazards.Each decal is attached close to a part of the machinewhere there is a possible hazard. Read and make sure youunderstand the safety message before you work with or onthat part of the machine.

Keep all decals clean and readable. Replace lost ordamaged decals. The decals and their attachment pointsare shown on the following pages. Each decal has a partnumber printed on it, use this number to order a new decalfrom your JCB distributor.INT-3-3-3

! 'O' rings, Seals and GasketsBadly fitted, damaged or rotted 'O' rings, seals andgaskets can cause leakages and possible accidents.Renew whenever disturbed unless otherwiseinstructed. Do not use Trichloroethane or paintthinners near 'O' rings and seals.INT-3-2-12

! CleaningCleaning metal parts with incorrect solvents can causecorrosion. Use only recommended cleaning agentsand solvents.INT-3-2-11

! Hydraulic HosesDamaged hoses can cause fatal accidents. Inspect thehoses regularly for:Damaged end fittingsChafed outer coversBallooned outer coversKinked or crushed hosesEmbedded armouring in outer coversDisplaced end fittings.INT-3-3-2

! WARNINGIf you need eye-glasses for reading, make sure you wearthem when reading the safety decals. Decals arestrategically placed around the machine to remind you ofpossible hazards. Do not over-stretch or place yourself indangerous positions to read the decals.INT-3-3-4

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SAFETY DECALS






7 7INTRODUCTION

SAFETY DECALS(continued)

4230-3

Note: All labels illustrated are in English. Your JCB Distributor will advise you on the availability of labels in other languages.

S263112






8 8INTRODUCTION

IDENTIFYING YOUR MACHINE

Machine Identification Plate

The machine identification plate is located as shown at A.The serial number of the machine and its major units arestamped on the plate.

Typical Vehicle Identification Number (VIN)

SLP 1CX S B V E 751601

World Manufacturer Identification

Machine Model

Machine Type (S = Standard, H = High-flow)

Build Type (A = Canopy, B = Cab)

Year of Manufacture:T = 1996 1 = 2001V = 1997 2 = 2002W = 1998 3 = 2003X = 1999 4 = 2004Y = 2000 5 = 2005

Manufacturer Location (E = England)

Product Identification Number (PIN)

Unit Identification

The engine serial number is stamped on a label B on theright side of the cylinder block.

The chassis serial number C is stamped on the front wallof the cab above the machine identification plate.

The hydraulic pump unit serial number is stamped on aplate on the bottom of the pump as shown at D.

If any of the above units are replaced with new ones, therelevant serial number on the Machine Identification Platewill be superseded. Either stamp the plate with the newnumber or stamp out the old number.

4230-5

203651

203640

D

C

A

S255430

B

1 2 3 4 5 6 7

1

2

3

4

5

6

7

CONSTRUCTOR MADE IN UK

J.C.BAMFORD EXCAVATORS LTD.ROCESTER, STAFFS, ENGLAND.R

Vehicle Identification No. Product Identification No.

ENGINE SERIAL No. WEIGHT

PUMP SERIAL No. YEAR OF MANUFACTURE

MODEL 80/1269/EEC MODEL 80/1269/EECPOWER KW R.P.M. POWER KW R.P.M.

160170

170 HF

32.534.4

260028002800

817/17187

1CX HF1CX

190190 HF1110

1110 HF34.42800 2800

56.856.865.365.3

220022002200220032.5 2600160 HF

RE

GIST ERE D

FIRM

BSI

34.4

34.4






9 9INTRODUCTION

JCB IMMOBILISER OPTION

4230-1

The JCB Immobiliser incorporates latest ElectronicImmobil iser technology and is operated by anElectronically coded key.

The components required to operate the JCB Immobiliserare:

Yellow JCB Immobiliser Electronically coded key.Instrument panel mounted Immobiliser key receptacle.

Follow the instructions below to Activate and Deactivatethe JCB Immobiliser system.

Activation

The vehicle is automatically immobilised 15 seconds afterswitching off the engine ignition system.

The L.E.D. (Light Emitting Diode) in the JCB Immobiliserkey receptacle flashes when the immobiliser is activated.

Deactivation

To start the vehicle engine the JCB Immobiliser Electronickey must be inserted and removed from the Immobiliserkey receptacle, the L.E.D. will then extinguish indicatingthe Immobiliser has deactivated. The vehicle ignition key isoperated to start the engine in the normal way but within 10to 15 seconds otherwise the system will reactivate itself.

If the Immobiliser key remains inserted in the receptaclethe engine will not start.

If the Immobiliser key is inserted in the receptacle forlonger than 15 seconds the L.E.D. in the Immobiliser keyreceptacle will begin to flash indicating activation of thesystem. To deactivate the Immobiliser first remove theelectronic key from the receptacle, then re-insert the keyand remove it within 5 to 10 seconds.

NEVER TURN OR ATTEMPT TO TURN THE JCBIMMOBILISER ELECTRONIC CODED KEY WHEN ITHAS BEEN INSERTED INSIDE THE KEY RECEPTACLE.

Additional and/or replacement Immobiliser Electronic keys(Maximum of 5 keys) can be supplied on request from yourapproved installing JCB distributor provided that one of thetwo Electronic keys originally supplied with the Immobiliseris still available.

S242160






21 21OPERATION

INTRODUCTION

The aim of this part of the handbook is to guide theoperator step-by-step through the task of learning how tooperate the machine efficiently and safely. Read theOPERATION section through from beginning to end.

Before starting the machine, sit in the operator's seat andfamiliarise yourself with the layout of the cab. Use yourhandbook to identify each control lever, switch, gauge,button and pedal. Do not guess. If there is anything youdo not understand, ask your JCB distributor.

The operator must always be aware of events happeningoutside the cab as well as inside the cab. Safety mustalways be the most important feature when operating theJCB 1CX.

The following checks should be made each time you returnto the machine after leaving it for any period of time. Weadvise you also to stop the machine occasionally duringlong work sessions and do the checks again.

All these checks concern the serviceability of the machine.Some concern your safety. Get your service engineer tocheck and correct any defects.

! WARNINGWalking or working under raised attachments can behazardous. You could be crushed by the attachmentsor get caught in the linkages.

Lower the attachments to the ground before doingthese checks. If you are new to this machine, get anexperienced operator to lower them for you.

If there is nobody to help you, study this handbookuntil you have learned how to lower the attachments.3-2-1-6

When you have familiarised yourself with the operatingcontrols and switches, practise using them. Drive themachine in an open space, clear of people. Get to knowthe 'feel' of the machine and its driving controls.

Finally, do not rush the job of learning, make sure you fullyunderstand everything in the OPERATION section. Takeyour time and work efficiently and safely.

Remember

BE CAREFULBE ALERTBE SAFE

1 Check for Cleanliness

a Clean the window and light lenses.

b Remove dirt and debris, especially from aroundthe linkages, rams, pivot points and radiator.

c Make sure the cab step and handholds are cleanand dry.

d Clean all safety decals. Replace any that aremissing or cannot be read.

2 Check for Damage

a Inspect the machine generally for damaged andmissing parts.

b Make sure that the shovel, bucket and bucketteeth are secure and in good condition.

c Make sure that all pivot pins are securedcorrectly in place.

d Inspect the window for cracks and damage.Glass splinters can blind you.

e Check for oil, fuel and coolant leakages.

4230-1

BEFORE ENTERING THE CAB






22 22OPERATION

BEFORE ENTERING THE CAB(continued)

!! WARNINGYou could be killed or injured if a machine tyre bursts.Do not use the machine with damaged, incorrectlyinflated or excessively worn tyres.2-2-1-2

3 Check the Tyres

a Make sure the tyres are correctly inflated, seeInflating the Tyres in MAINTENANCE sectionfor a safe procedure for inflating the tyres.

b Check for adequate tread depth, cut rubber andpenetration by sharp objects. Do not use amachine with damaged tyres.

4 Check the Fuel and Hydraulic Filler Caps

Make sure the caps are tightly closed. (We alsorecommend that, if possible, you lock the filler caps.)

!! WARNINGDo not use the machine controls as handholds whenentering (or leaving) the machine.2-2-1-4

!! CAUTIONAlways face the machine when entering (and leaving)the cab. Make sure your hands and shoes are cleanand dry. Otherwise you could slip and fall.2-2-1-3

Be careful when entering or leaving the cab, especially ifthe engine is running. Make sure that the engine isrunning at no more than a slow idling speed. Turn the seatso that it is facing the door as shown at A, this will isolatethe loader and drive control joysticks. If you do not turnthe seat, the machine or its attachments could move if youaccidentally touch the controls when getting in or out.

5 Check the Engine Compartment Side Panels andBonnet

a Make sure the engine compartment side panelsare fitted and secured correctly (see EngineCompartment Access in MAINTENANCEsection).

b Make sure the bonnet is closed and locked (seeEngine Compartment Access inMAINTENANCE section ).

6 Check Condition of the Seat Belt

Make sure the seat belt is working correctly and isnot damaged (see Seat Belt ).

4230-2

ENTERING/LEAVING THE CAB

S207361

A






23 23OPERATION

ENTERING/LEAVING THE CAB(continued)

Backhoe Control Lever Lock (if fitted)

To prevent the backhoe from being accidentally operatedwhen the driver is entering or leaving the cab, and drivingon the highway, a safety locking pin A can be installed.

Always fit the locking pin before leaving the cab. Onlyremove the locking pin when you are correctly seatedinside the cab. Put the pin in its stowage position B duringmachine operation. This will prevent the pin from beingmisplaced.

Leaving the Cab in an Emergency

! WARNINGThe ROPS cab is designed to give you protection in anaccident. If you do not wear your seat belt, you couldbe thrown about inside the cab, or thrown out of themachine and crushed. You must wear a seat belt whenusing the machine. Fasten the seat belt before startingthe engine.2-2-1-9

! WARNINGRollover

Should the machine start to roll over, you can becrushed if you try to leave the cab. If the machinestarts to roll over, DO NOT TRY TO JUMP FROM THECAB. STAY IN THE CAB, WITH YOUR SEAT BELTFASTENED.INT-2-1-12

When the machine comes to rest following an accident,switch the starter key to the OFF position, if at all possible,and remove the seat belt.

The cab light is fitted with a sliding switch C - slide itupwards to switch on the light.

If the machine is lying on its side preventing exit throughthe door, open the rear window and carefully climb out.

4230-2

S259360

A

B

CAB LIGHT(Cab Machines only)

S213520

C






24 24OPERATION

DOOR AND WINDOWS(Cab Machines only)

The cab has one door, an opening rear window and anopening side window.

Note: Do not drive the machine with the door unlatched,otherwise it could swing open.

Opening and Closing the Door

To open the door from the outside, unlock it with the keyprovided and press the lock barrel.

Close the door from the inside by pulling it firmly; it willlatch itself. To open the door from the inside, pull lever Aup.

Opening and Closing the Rear Window

To open the rear window, take a firm grip on the twohandles A and press lever B on both sides to release thelock mechanism.

Pull the window towards the front of the machine and up asfar as it will go. Release lever B then make sure thewindow latches in the open position.

To close the window, press lever B on both sides torelease the lock mechanism then lower the window to theclosed position. Release lever B then make sure thewindow latches in the closed position.

4230-2

S213510

B

A

S213501

A






25 25OPERATION

SEAT BELT

! WARNINGDo not use a seat belt which is damaged orexcessively worn.

Do not use a seat belt that has been in an accident.

A worn, damaged or already stressed seat belt couldbreak or give way in a collision. If that happens youcould be killed or injured.2-2-3-8

! WARNINGSeat Belt

Operating the machine without a seat belt can bedangerous. Before starting the engine, make sure yourseat belt is fastened. Check the tightness andcondition of the seat belt securing bolts regularly (seemaintenance schedules).INT-2-1-8/1

Fastening the Seat Belt

1 Sit correctly in the seat. Remove the male fitting Afrom its stowage and position it across your lap.

2 Push the male fitting A into the buckle B until itlatches into position. Make sure the seat belt is nottwisted.

3 Adjust the belt length until it makes a snug fit.

Note: If the belt 'locks' before the male fitting A has beenengaged, allow the belt to fully retract in its reel holder andthen try again. The inertia mechanism may lock if you pullthe belt too sharply or if the machine is parked on anincline. In such cases, ease the belt gently from its reelholder.

Releasing the Seat Belt

1 Press button C and pull the male fitting A from thebuckle B.

2 Let the seat belt retract into its reel holder.

3 Replace male fitting A in its stowage.

Checking Seat Belt Operation

1 Sit correctly in the seat and fasten the seat belt asdescribed.

2 Take hold of the seat belt and tug. The seat beltshould 'lock'.

If the seat belt does not 'lock' when the above test isperformed, get the seat belt repaired or replaced.

4230-2

106842

106842

106842

C

BA






26 26OPERATION

CAB LAYOUT

4230-4

202411

S202423

8

5 5

7

2 1

4

Note: The illustration shows the seat swivelled to the rearwards position for excavator operation.

3

96






1 Drive Control LeverThe lever controls forward/reverse drive and steering.It is spring loaded to its central (neutral) position. SeeGetting the Machine Moving.

2 Loader Arm/Shovel Control LeverThe lever controls arms lift and lower and bucket openand close. It is spring loaded to its central (neutral)position. See Loader Controls.

3 Hand Throttle LeverOnce the engine has started, set the lever to give anengine speed suitable for the condit ions andoperations to be performed.

4 Throttle Foot PedalUse the foot pedal, when driving or using the loader,to increase the engine speed by overriding the settingof the hand throttle lever. When the pedal is releasedthe engine speed reverts to that set by the handthrottle lever.

5 Backhoe Control LeversSee Backhoe Controls.

6 Stabiliser Control LeversSee Stabiliser Controls.

7 Instrument PanelSee Switches, Warning Indicators and Hourmeter.

8 Seat Control LeverSee Seat Controls.

9 Fuel GaugeShows the amount of fuel left in the tank.

27 27OPERATION

CAB LAYOUT(continued)

4230-4






28 28OPERATION

HEATER CONTROLS(Cab Machines only)

Hot air is directed to the front and rear screens and, bymeans of vent A, to the footwell. A heater control switch Bcontrols a two-speed heater fan.

Air Control. Close vent A to direct all the air to the frontand rear screens.

Heater Fan Switch. Press the switch B down to switch onthe fan. Press further down to select high speed.

The heater control tap C is situated in the enginecompartment on the right hand side of the engine. The tapmust be in the on position D for warm air. Turn the tap tothe off position E for cold air.

Switches

1 Starter SwitchSee Starting the Engine.

2 Auxiliary Attachments Control SwitchSee Loader Controls.

3 Horn ButtonPress to operate the horn. The horn will operate onlywhen the starter switch is set to IGN.

4 Override ButtonPressing this button enables use of the loader and,providing the parking brake is off, repositioning of themachine when the seat is facing towards the rear ofthe machine.

5 Parking Brake Control SwitchThe machines brakes are applied automaticallywhenever the engine is stopped. However, it may benecessary to apply the brakes while the engine is stillrunning, e.g. when using a static attachment such asan auger.

This control can also be used in an emergency tostop the machine almost instantly.

Note: Such usage should only be undertaken as a lastresort since the brake mechanism can be damaged. Getthe brakes checked after an emergency stop.

Switch operation up to machine no. 807705Press the switch down to apply the brakes. Theswitch will illuminate. Press the switch up to releasethe brakes. Check that the switch extinguishes.

4230-2

SWITCHES AND INSTRUMENTS

S214001

B

A

S256890

C

E

D






29 29OPERATION

SWITCHES AND INSTRUMENTS(continued)

Switches (continued)

5 Parking Brake Control Switch (cont’d)Switch operation from machine no. 807706Press down to apply the brakes. The switch willilluminate. Slide lock then press up to release thebrakes. Check that the switch extinguishes.

6 Hazard Warning Lights Switch (if fitted)Press down to switch on the hazard warning lights.

7 Direction Indicator Switch (if fitted)Press left or right to indicate changes of directionwhen driving.

8 Auxiliary Attachments Detent SwitchSee Loader Controls.

9 Hand Held Attachment Switch (if fitted)Press down to switch on the hand held attachmenthydraulic circuit.

10 Beacon Light SwitchPress to switch on the flashing beacon. See RotatingBeacon.

11 Road Lights Switch (if fitted)Press down to switch on the sidelights. Press furtherdown to switch on the headlights.

12 Front Work Light SwitchPress down to switch on the front work lights.

13 Rear Work Light SwitchPress down to switch on the rear work lights.

14 Windscreen Wipe/Wash Switch Press down to operate the wiper. Press further todirect the wash fluid onto the windscreen. The switchis spring loaded and returns to the middle (wipe)position when released.

15 Float Control Switch (if fitted)See Loader Controls.

16 High-flow Hydraulic SwitchSee Loader Controls.

4230-5

S202436

1

£5 6 7 8

3

9 0 ! @ $

2

% ^

Note: The switches shown may not all be fitted to your machine, also the switch positions may be different.

382150

P P

4






30 30OPERATION

SWITCHES AND INSTRUMENTS(continued)

Warning Indicators

Lamps

1 Engine Speed IndicatorFitted to machines manufactured from October 1997.Illuminates when engine is running within the correctspeed band for backhoe operation.

Lamps Plus Audible Alarm

!! CAUTIONIf any audible/visual warnings operate whilst theengine is running, stop the engine as soon as it is safeto do so and rectify the fault.4-2-1-2

With the following, there is an audible warning as well asthe warning light.

2 No Charge Lights when the starter switch is set to IGN beforestarting the engine. The light should go out a fewseconds after the engine starts. Also lights if thebattery charging circuit fails while the engine isrunning.

3 Air Filter BlockedLights if the engine air filter is blocked.

4 Engine Oil Pressure Lights if the engine oil pressure drops too far. Lightswhen the starter switch is set to IGN before startingthe engine but should go out when the engine starts.If this light remains on stop the engine immediately.SERIOUS ENGINE DAMAGE COULD OCCUR IFTHIS WARNING IS IGNORED.

5 Low Hydraulic Charge PressureLights if the hydraulic charge pressure drops too far.Lights when the starter switch is set to IGN beforestarting the engine but should go out when theengine starts. If this light remains on stop the engineimmediately. SERIOUS TRANSMISSION DAMAGECOULD OCCUR IF THIS WARNING IS IGNORED.

Note: A blocked hydraulic oil filter is a possible cause oflow hydraulic charge pressure.

6 Water Temperature High Lights if the engine coolant overheats. Also lights ifthe engine coolant level falls too far.

7 Hydraulic Oil Temperature HighLights if the hydraulic oil temperature rises too far.

Hourmeter

The Hourmeter 8 records the total running time of theengine. Use it to keep a check of running hours betweenmaintenance intervals.

4230-3

S202444

7

6

5

4

2

31

8






31 31OPERATION

SEAT CONTROLS

The operator's seat can be adjusted for your comfort. Acorrectly adjusted seat will reduce operator fatigue.Position the seat so that you can comfortably reach themachine controls.

The seat can be turned to face the backhoe controls.Remember to adjust it again if necessary.

The seat adjustments are as follows:

Fore/Aft

Move lever A upwards and slide the seat to the positionyou want. Release lever A. Make sure the seat is locked inposition.

Swivel

Move lever A upwards and slide the seat fully rearwards.Swivel the seat to face the opposite direction. Releaselever A. Make sure the seat latches in position.

Note: To ensure the seat fully latches into position it mustbe pushed firmly rearwards.

Loader Arm/Shovel Control Lever

Lever B controls the movement of the loader arm and theshovel (or any other attachment which is installed on theloader arm).

The lever has four main movements and is spring-loadedto its central (hold) position.

The speed of loader/shovel movement depends on howfar you move the lever; the further you move the lever thefaster the action.

The main lever movements are shown right. Their effectsare described below. Combined actions can be achievedby moving the lever diagonally. The lever movements andresulting actions are shown on a decal on the cab frontwall.

1 To raise the loader arm pull the lever back.

2 To lower the loader arm, push the lever forward.

3 To roll the shovel forward (dump), push the lever tothe right.

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

4230-4

S202503

4 1

32

B

202401

A

LOADER CONTROLS






32 32OPERATION

LOADER CONTROLS(continued)

Auxiliary Attachments Control Switches(optional)

Two switches C situated on the Loader Control Lever areused to actuate the hydraulic function of an attachment.Refer to OPTIONAL ATTACHMENTS section or, ifappropriate, the instructions supplied with the attachment,for details of the function controlled.

Earlier machines are fitted with a three position rockerswitch situated on the top of the Loader Control Lever.The switch is spring returned to the central OFF position.

Auxiliary Attachments Detent Switch(optional)

Some attachments require more continuous working thanothers, e.g. an auger. A three position detent switch D(ON-FORWARD/OFF/ON-REVERSE) is provided on thepanel. When pressed ON (FORWARD or REVERSE), theattachment wil l run without uti l ising the Auxil iaryAttachment Control Switches C. FORWARD or REVERSEshould be selected as required. Press the detent switch tothe centre position to switch OFF. The actual forward orreverse direction will depend on the attachment beingused.

!! CAUTIONThe auxiliary attachments detent switch must beselected to its centre OFF position when noattachments are fitted. Otherwise damage to thehydraulic system can result due to overheating.3-2-1-7

High-flow Hydraulic Switch (optional)

Certain attachments require a higher than normalhydraulic flow for efficient operation.

To select high-flow, first start the engine then press threeposition switch E fully down. When released, the switchwill spring return to its central position and the high-flowcircuit will remain selected. The circuit will automaticallyde-select when the engine stops. The engine cannot bestarted unless the high-flow switch is turned OFF (fully up).

The High-flow switch must always be in the OFF positionunless a high-flow attachment is fitted.

Note: High-flow hydraulics will not operate if the enginespeed is too low.

Float Control Switch (optional)

This option allows the loader arm and bucket to 'float'.When selected the bucket is free to ride up and down overthe ground as the machine travels. Press the switch F downto select Float. Press the switch up to deselect Float.

! CAUTIONIf Float is selected with the loader raised, the loaderwill descend to ground level and 'float' across it as youtravel. You will not have control over the rate of fall.2-2-2-7

Always lower the loader before selecting Float.

Note: Float will be automatically de-selected if the armsraise control is operated.

4230-4

S202514

D E

S202503B

C

F






33 33OPERATION

STABILISER CONTROLS

! WARNINGYou must be sitting in the driving seat when operatingthe stabiliser controls.

Do not operate the stabilisers from outside themachine. Otherwise you could be crushed when themachine moves.

The stabilisers must be down when you use thebackhoe, or the machine will rock violently. Eachstabiliser has its own control lever and can beoperated independently.

Lower each stabiliser to level the machine and take theweight off of the rear tyres. The loader bucket shouldbe used along with the stabilisers to level and steadythe machine.2-2-2-8/1

! WARNINGBystanders could be crushed and obstacles could bedamaged if they are beneath the stabilisers while theyare being lowered. Before lowering the stabilisers,make sure any bystanders are clear of the machine.Also make sure that there are no obstacles beneaththe stabilisers.2-2-2-10

Raise Stabilisers

To raise the stabilisers A and C and lower the machine,push the levers towards the rear of the machine. Thestabilisers must be fully raised before the machine can bedriven off.

The fully raised position of the stabilisers is indicated whenthe 'flags' E (one on each stabiliser) are fully visible.

The stabilisers may be locked in the fully raised position byinserting pin F through the holes in the flag and lifting eyeas shown.

! CAUTIONEnsure that the stabiliser lock pin is removed beforeoperating the stabiliser control otherwise the pin andflag may be damaged.3-2-1-8

Lower Stabilisers

To lower the stabilisers B and D and raise the machine,pull the levers towards the front of the machine.

4230-1

S202491

202520

A

B D

C

B

A

D

C

EF






34 34OPERATION

BACKHOE CONTROLSJCB X Pattern

JCB X Pattern

! WARNINGDo not operate the backhoe controls from outside themachine, or you could be crushed by the backhoe.2-2-3-1

Note: In this section of the handbook, 'left' and 'right' meanyour left and right when seated correctly in the machine,facing the backhoe.

On machines with the JCB X Pattern control, the left handlever L operates the boom and slew. The right hand leverR operates the dipper and bucket. The stabilisers areoperated as described in Stabiliser Controls.

Each lever has four main movements (in a 'X' pattern), andis spring-loaded to its central (hold) position. The backhoewill stay in any position until you move it with the levers.

Both levers can be moved at the same time, for moreefficient operation. The speed of backhoe movementdepends on how far you move the lever; the further youmove the lever the faster the action.

Combined actions can be achieved by moving the lever indirections between the four main ones. The levermovements and resulting actions are shown on a decalnear the controls.

Note: Green indicator light S will illuminate when theengine is running within the correct speed band foroperating the backhoe.

4230-2

S202532

L R

S






35 35

Boom and Slew Movements

1 To raise the boom A, pull the lever diagonally left andtowards you. Before raising the boom check that it isclear overhead.

2 To lower the boom B, push the lever diagonally rightand away from you.

3 To slew the boom to your left C, move the leverdiagonally left and away from you.

4 To slew the boom to your right D, move the leverdiagonally right and towards you.

Note: Some backhoe buckets and attachments may collidewith the stabiliser legs if slewed too far round. Check thisbefore using different attachments.

4230-1

OPERATION

BACKHOE CONTROLSJCB X Pattern (continued)

S202571 S202561

C

DA

B

A

B

CD






36 36OPERATION

BACKHOE CONTROLSJCB X Pattern (continued)

Dipper and Bucket Movements

1 To bring the dipper in E, pull the lever diagonally rightand towards you.

Note: Some backhoe attachments may collide with theboom if brought too far in. Check this before using differentattachments.

2 To push the dipper out F, push the lever diagonallyleft and away from you. If the boom is already up,check that it is clear overhead before swinging thedipper out.

3 To close the bucket G (say to gather a load), pull thelever diagonally left and towards you.

4 To open the bucket H (say to dump a load), push thelever diagonally right and away from you.

4230-1

S202551 S202541

G

H

E

F

F

E

G

H






37 37OPERATION

BACKHOE CONTROLSJCB + Pattern

JCB + Pattern



On machines with the JCB + Pattern control, the left handlever L operates the boom and slew. The right hand leverR operates the dipper and bucket. The stabilisers areoperated as described in Stabiliser Controls.

Each lever has four main movements (in a '+' pattern), andis spring-loaded to its central (hold) position. The backhoewill stay in any position until you move it with the levers.


Combined actions can be achieved by moving the leverdiagonally. The lever movements and resulting actions areshown on a decal near the controls.


4230-2

S202582

RL

S






38 38OPERATION

BACKHOE CONTROLSJCB + Pattern (continued)

Boom and Slew Movements

1 To raise the boom A, pull the lever towards you.Before raising the boom check that it is clearoverhead.

2 To lower the boom B, push the lever away from you.

3 To slew the boom to your left C, move the lever toyour left.

4 To slew the boom to your right D, move the lever toyour right.


4230-1

S202611 S202621

C

A

B

BCD

A

D






39 39OPERATION

BACKHOE CONTROLSJCB + Pattern (continued)

Dipper and Bucket Movements

1 To bring the dipper in E, pull the lever towards you.


2 To push the dipper out F, push the lever away fromyou. If the boom is already up, check that it is clearoverhead before swinging the dipper out.

3 To close the bucket G (say to gather a load), movethe lever to your left.

4 To open the bucket H (say to dump a load), move thelever to your right.

4230-1

S202591S202601

G H

F

E

F

E

G

H






40 40OPERATION

BACKHOE CONTROLSISO Pattern

ISO Pattern



On machines with ISO Pattern control, the left hand lever Loperates the slew and dipper. The right hand lever Roperates the boom and bucket. The stabilisers areoperated as described in Stabiliser Controls.

Each lever has four main movements (in a '+' pattern), andis spring-loaded to its central (hold) position. The backhoewill stay in any position until you move it with the levers.


Combined actions can be achieved by moving the leverdiagonally. The lever movements and resulting actions areshown on a decal near the controls.


4230-2

S202632

RL

S






41 41OPERATION

BACKHOE CONTROLSISO Pattern (continued)

Dipper and Slew Movements

1 To bring the dipper in A, pull the lever towards you.


2 To push the dipper out B, push the lever away fromyou. If the boom is already up, check that it is clearoverhead before swinging the dipper out.

3 To slew the boom to your left C, move the lever toyour left.

4 To slew the boom to your right D, move the lever toyour right.


4230-1

S202671 S202661

DC

A

B

A

B

D C






42 42OPERATION

BACKHOE CONTROLSISO Pattern (continued)

Boom and Bucket Movements

1 To raise the boom E, pull the lever towards you.Before raising the boom check that it is clearoverhead.

2 To lower the boom F, push the lever away from you.

3 To close the bucket G (say to gather a load), movethe lever to your left.

4 To open the bucket H (say to dump a load), move thelever to your right.

4230-1

S202651 S202641

HG

E

F

F

E

G

H






43 43OPERATION

HYDRACLAMPS

The hydraclamps are released by pulling knob A fully up. Anearby decal shows the lever movements and clampactions. For detailed instructions on operating the clampssee Sideshifting the Backhoe .

1 To release the clamps, pull the knob fully up.

2 To tighten the clamps, push the knob fully down thenoperate boom up to its maximum position andcontinue to operate the boom up control for 2 - 3seconds.

Some machines have a foot operated pedal B. This is usedto operate certain backhoe attachments.

The pedal is a rocking type operated by heel-and-toe. It isspring loaded to its mid-position. Speed of operationdepends how far the pedal is pressed down. Theattachment will stay in any position until you move thepedal.

Note: The foot operated pedal must be locked when not inuse. If the pedal is accidentally operated the machinecould be damaged.

To lock the pedal, move lock C in direction D. To unlockthe pedal move lock C in direction E.

4230-1

S202461

A

S214020

B

C CDE

FOOT OPERATED PEDAL






44 44OPERATION

BEFORE STARTING THE ENGINE

Note : Read Operating in Low Temperatures orOperating in High Temperatures if you will be using themachine in very cold or very hot climates.

1 Make Safe the Loader Shovel

The loader shovel should already be resting on theground. If it is not you should, if possible, install thesafety strut provided (see Installing the Safety Strutin MAINTENANCE section). Alternatively, block theshovel to prevent any chance of it falling.

2 Do a Pre-Start Inspection

For your own safety (and others') and for maximumservice life of your machine, do a pre-start inspectionbefore starting the engine.

a If you haven't already done it, do a walk roundinspection of the outside of the machine (seeBefore Entering the Cab).

b Remove dirt and rubbish from the cab interior,specially around the pedals and control levers.

! WARNINGKeep the machine controls clean and dry. Your handsand feet could slide off slippery controls. If thathappens you will lose control of the machine.2-2-3-6

c Remove oil, grease and mud from the pedalsand control levers.

d Make sure that your hands and shoes are cleanand dry. (See WARNING above.)

!! CAUTIONLoose articles can fall and strike you or roll on thefloor. You could be knocked unconscious, or thecontrols could get jammed. If that happens you willlose control of the machine.2-2-3-7/1

e Remove or secure all loose articles in the cab -such as lunch boxes, tools etc.

f Inspect the ROPS/FOPS structure for damage.Get your JCB distributor to repair any damage.

g Check round the cab for loose or missing bolts,screws etc. Replace or tighten where necessary.

! WARNINGReplace the seat belt with a new one if it is damaged,if the fabric is worn, or if the machine has been in anaccident. Fit a new seat belt every three yearsregardless of condition.2-3-1-8

h Inspect the seat belt and its mountings fordamage and excessive wear.

i Check that the following (as applicable) are inworking order:Lights, warning lights, rotating beacon, indicatorlights, all switches, windscreen washer andwipers.

Do the following after entering the machine and closingand latching the door (if fitted).

3 Adjust the Seat

Adjust the seat (see Seat Adjustment), so that youcan comfortably reach all the operating controls.

4 Fasten and Adjust the Seat Belt

See Seat Belt.

5 Ensure the Drive Control is in Neutral

If the engine is started with the drive control deflectedto either the forward or reverse position the machinewill lurch forward or backwards. The control is springloaded to return to neutral, but ensure that nothinghas caused the lever to be deflected.

6 Ensure the Loader Control Lever and All theBackhoe Levers are in Neutral

If the engine is started with any of the excavatingcontrol levers deflected from their neutral position,some part of the machine may move. The levers arespring loaded to return to their neutral positions, butensure that nothing has caused any of them to bedeflected.

7 Ensure the Auxiliary Attachments Detent andHigh-flow switches are off.

The engine will not start if either the AuxiliaryAttachments Detent Switch or the High-flow switch ison.

8 Parking Brake Light

Ensure that the door is ful ly closed (cabbedmachines). Unless the parking light extinguisheswhen the brake is switched off no hydraulic pressurewill be available to the drive motors even though theengine is running.

4230-5






45 45OPERATION

STARTING THE ENGINE

1 Ensure that the Drive Control Lever is in the neutralposition (see Step 5 on previous page) and theAuxiliary Attachments Detent Switch D is in the offposition.

2 Set the Hand Throttle Control B to its maximumposition.

3 Turn Starter Key C to pre-position H for a fewseconds.

4 Turn the Starter Key fully clockwise against the springto position HS to start the engine.

5 As soon as the engine starts, release the key whichwill return to the IGN position. Slowly reduce the handthrottle setting to allow the engine to idle.

6 Once the engine has warmed up, set the HandThrottle Control as required.

Note: Make sure all the warning lights are OFF when theengine is running.

If any warning l ights remain on, stop the engineimmediately and investigate the cause.

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46 46OPERATION

JUMP-STARTING THE ENGINE

! WARNINGIf you try to charge a frozen battery, or jump-start andrun the engine, the battery could explode.

Do not use a battery if its electrolyte is frozen. Toprevent the battery electrolyte from freezing, keep thebattery at full charge.

Batteries give off a flammable gas that can explode.

Do not smoke when checking the battery electrolytelevels. When starting from another machine, makesure the two machines do not touch. This prevents anychance of sparks near the battery. Sparks could ignitethe battery gas. If that happens the battery couldexplode.

Even with the starter switch set to off some circuitswill be energized when the external power supply isconnected. Set all the machine switches to their OFFpositions before connecting the external powersupply.

Do not connect a booster supply directly across thestarter motor. Doing this could bypass the neutralsafety switch and the engine can start with thetransmission in gear. The machine could then runaway and kill or injure bystanders.

Use only booster cables which are in good conditionwith securely attached connectors. Connect both endsof one booster cable before connecting the other one.5-2-2-3

1 Make Safe the Loader Shovel

The loader shovel should already be resting on theground. If it is not you should, if possible, install thesafety strut supplied (see Installing the Safety Strutin MAINTENANCE section). Alternatively, block theshovel to prevent any chance of it falling.

2 Set All Switches in the Cab to Off

3 Connect the Booster Cables

a Remove the battery compartment cover.

! WARNINGKeep metal watch straps and any metal fasteners onyour clothes, clear of the positive (+) battery terminal.Such items can short between the terminal and nearbymetalwork. If this happens you can get burned.

Make sure that the fuel filler cap is tightly fitted. Makesure that all spilt fuel is cleaned away from the batteryarea.2-2-4-2

b Connect the positive booster cable to the positive( + ) terminal on the machine battery. Connectthe other end of this cable to the positive ( + )terminal of the booster supply.

c Connect the negative ( - ) booster cable to agood frame earth on the machine, away fromand below the battery.

Note: A good frame earth is part of the main frame, freefrom paint and dirt. Do not use a pivot pin for an earth.

d Connect the other end of this cable to thenegative ( - ) terminal on the booster supply.

4 Do the Pre-Start Checks

See Steps 3 to 8 of Before Starting the Engine.

5 Start the Engine

See Starting the Engine.

6 Disconnect the Booster Cables

a Disconnect the negative booster cable from themachine frame earth. Then disconnect it from thebooster supply.

b Disconnect the positive booster cable from theposit ive (+) terminal on the battery. Thendisconnect it from the booster supply.

c Refit and secure the battery compartment cover.

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47 47OPERATION

PREPARING THE MACHINE FOR TRAVEL

When travelling on the road or on site there are usuallylocal rules and safety regulations for the machine travellingposition. 'Travelling on Site' and Travelling on the Road'described on the following pages are recommendationsthat should help you to meet the requirements of theseregulations; they are not necessarily the applied law:

PLEASE MAKE SURE THAT BEFORE TRAVELLING ONSITE OR ON THE ROAD, YOU AND YOUR MACHINECOMPLY WITH ALL THE RELEVANT LOCAL LAWS - ITIS YOUR RESPONSIBILITY.

Whether driving on the road or on site, the machineposition must satisfy the following requirements:

1 The attachments must not cause the maximum overallmachine width to exceed 2.5 m (8.2 ft). If any partprotrudes beyond the outer edge of the rear frame, itmust be marked with red and white stripes to warnthat a hazard exists.

2 The boom/slew lock must be engaged.

3 In certain territories, it will be necessary to fit a bucketcrowd ram safety strut.

4 The attachments must not protrude from the back ofthe machine by more than 1m (3.28ft). If theattachments do protrude by more than 1m (3.28ft)then a rear protrusion plate/light must be installed. Ifthe attachment is removed the tipping link must besecured.

5 Machine stability must be maintained.

6 On the road, the rear stop/tail indicator lights (bothsides) must be clearly visible from the rear of themachine (see CAUTION on the following page).

7 The hydraclamps must be engaged.

Travelling On Site

! WARNINGA high loader shovel can block your view and reducethe stability of the machine. Travel with the loader lowto the ground. Travel slowly and with caution overrough, muddy or loose surfaces.2-1-1-3

Note: Some attachments may require different travelpositions to those described below. See OPTIONALATTACHMENTS or the instructions supplied with theattachment.

Read and understand the information given in the previousparagraphs. The recommendations given below ARE NOTnecessarily the applied law, please make sure you arecomplying with the relevant local laws.

1 Roll the bucket fully back. Raise it to clear the roadsurface by 300 mm (12 in) as shown at A.

2 Position the boom and dipper across the back of themachine, as shown at B, and secure the buckettipping link. Engage the hydraclamps and boom andslew lock. See Stabiliser Controls and Boom/SlewLock.

3 If any attachments are fitted, make them safe.

Unless you are using pallet forks to carry a load, theforks must be removed. Refer to Pallet Forks inOPTIONAL ATTACHMENTS section.

4 Make sure the stabilisers are fully up. See StabiliserControls .

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48 48OPERATION

PREPARING THE MACHINE FOR TRAVEL(continued)

Travelling on the Road

! CAUTIONIt is illegal to travel on public highways without properroad lights. DO NOT take the machine on publichighways unless it is equipped with the optional roadlight kit.3-2-1-1

! WARNINGDo not drive on the road with the work lights switchedon. You can dazzle other drivers and cause anaccident.2-2-2-5

Read and understand the information given on page 47.The recommendations given below ARE NOT necessarilythe applied law, please make sure you are complying withthe relevant local laws.

1 Install the Backhoe Bucket Inside the LoaderShovel

All attachments should be removed before travellingon the road. However, if the machine IS driven on theroad with attachments fitted, then the conditions listedon page 47 should be maintained.

Install the backhoe bucket inside the loader shovelusing bucket mounted hanger bracket as shown at A.Roll the bucket fully back. Raise it to clear the roadsurface by 300 mm (12 in).

2 Set the Backhoe

Position the boom and dipper across the back of themachine, as shown at B on page 47, and secure thebucket tipping link. Engage the hydraclamps andboom and slew locks. See Stabiliser Controls andBoom and Slew Locks.

3 Make Safe All Attachments

If any attachments are installed, make them safe, forexample, fit tooth guards etc.

Note: In certain territories you will be breaking the law ifyou do not fit a tooth guard to the loader bucket. It mayalso be necessary to fit travel struts. Make sure you arecomplying with local laws.

4 Raise the Stabiliser Legs

Make sure the stabilisers are fully up. See StabiliserControls.

5 Check the Lamps

Check that the road lamps, including the flashingbeacon, are all in working order and clearly visible.

Note: We recommend that a flashing beacon is installedwhen the machine is travelling on public highways. Incertain territories you will be breaking the law if you do notinstall a flashing beacon when travell ing on publichighways - make sure you are complying with local laws.

Travelling on the Road (UK only)

In the U.K., before travelling on public roads, it is yourresponsibility as a user to comply with The Road Vehicles(Construction and Use) (Amendment) Regulations 1997(“Bridge Bashing Regs.”). By way of guidance only, thefollowing steps may be taken to comply:

1 Always assess your route for overhead structures suchas bridges which could be damaged by your machine.

2 Utilise the restraint device (described) to ensure thatthe equipment is in the travelling position.

IMPORTANT NOTE: Whilst this information is believed tobe correct, JCB cannot be aware of all circumstances inwhich JCB machines may be operated on a PublicHighway and it is the responsibility of the user to ensurecompliance with the regulations.

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49 49OPERATION

PREPARING THE MACHINE FOR TRAVEL(continued)

Travelling on the Road (UK only)(continued)

Carry out all the procedures covered on the previous pageand, in addition, do the following:

1 Disable the Loader Lift Service

Fully lower the loader arms and crowd the shovel fullyback. Stop the engine.

Machines up to serial no. 806864Remove the floor mat and the left hand floor plate (seeRemoving Floor Plates in Maintenance section).

Machines from serial no. 806865Remove the floor mat and the rear floor plate (seeRemoving Floor Plates in Maintenance section).

Move the lever A in the direction shown to disable theloader service.

Replace the floor plate and mat.

2 Fit the Dipper Ram Locking Strut

Set the backhoe as described on the previous pageand fit the boom and slew locks (see Boom/SlewLock).

Remove the ram strut from its stowage position B andplace around the dipper ram as shown.

Secure the strut into position using strap C.

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50 50OPERATION

BOOM/SLEW LOCK

The JCB 1CX is fitted with a combined boom and slewlocking device, which is designed to lock the boom in thefully raised position and slewed fully to the left, i.e. in thetravel position.

Engage the Boom/Slew Lock

! WARNINGYou or others can be killed or seriously injured if youoperate the control levers from outside the cab.Operate the control levers only when you are correctlyseated inside the cab.INT-2-1-3

! WARNINGIf two people are doing this job, make sure that theperson working the controls is a competent operator. Ifthe wrong control lever is moved or the controls aremoved violently, the other person could be killed orinjured.2-2-6-5

1 Move the kingpost carriage fully over to the right handside of the machine (see Sideshifting the Backhoe).

2 Fully raise the boom and slew the backhoe fullyacross the machine as shown at A.

3 Stop the engine.

4 Exit the cab.

5 Move lever B out of the detent position and across themachine until the spring loaded pins engage, lockingthe boom into position.

Note: The boom may also be locked in the fully raisedposition independently of the slew position. This is shownin the illustration.

Release the Boom/Slew Lock

1 Start the engine and take the weight of the boom byraising the boom slightly. Stop the engine.

2 Exit the cab.

3 Move lever B away from the boom and across themachine into the detent position.

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51 51OPERATION

ROTATING BEACON

The rotating beacon has a magnetic base for securing it tothe roof of the cab. It plugs into jack socket B as shown.The socket is protected by a hinged cap which lifts forfitting the jack plug.

To switch the beacon on or off, operate the switch on thecontrol panel. See Controls, Switches and Instruments.

Note: After removing the plug, the cap will be closed by thespring hinge.

Note: DO NOT leave the beacon on the cab roof when notin use. Return it to its storage position.

! WARNINGBefore testing the parking brake make sure the areaaround the machine is clear of people.2-2-4-5

Test the brake on a level, dry surface.

Make sure your seat belt is securely fastened.

! WARNINGDo not drive the machine without wearing the seat belt,properly fastened and adjusted.2-2-3-9

1 Raise the Attachments

The attachments should already be in the travellingposition (see Preparing the Machine for Travel ).

2 Make Sure the Parking Brake is Engaged

The parking brake is engaged when the parking brakeswitch is illuminated.

3 Test the Brakes

a Make sure that there are no obstructions orpeople in front of or behind the machine, thenslowly operate the Drive Control to forward orreverse. The machine should not move.

b If the machine has not moved, use the FootThrottle to gradually increase the engine speedto its preset maximum. The machine should notmove.

c Reduce the engine speed to idle and set theDrive Control to neutral.

Note: If the machine moved during the test, have your JCBdistributor inspect the brake. Do not use the machine withfaulty brakes.

! WARNINGDo not use a machine with a faulty parking brake.3-2-3-10

! CAUTIONNon approved modifications to drive ratios, machineweight or wheel and tyre sizes may adversely affectthe performance of the parking brake.3-2-2-11/1

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P






52 52OPERATION

GETTING THE MACHINE MOVING

Before attempting to drive the machine, read theOperating Procedures and WARNING first.

Drive Control Lever

The machine is driven solely by use of the Left HandControl Lever A. This lever performs two functions:forward/reverse drive and steering. It is spring loaded toits central (neutral) position.

Forward/Reverse Drive. Starting from the lever neutral (N)position, select forward drive by pushing the leverforwards, or select reverse drive by pulling the lever back.The amount of lever movement controls the speed of themachine; the greater the movement the faster the speed.

An optional reverse alarm is available. When reverse isselected the alarm automatically sounds to warn passers-by.

Steering is achieved in both forward and reverse drive (i.e.with the lever forward or back) by moving the lever to theleft to turn left or to the right to turn right. The greater thetravel of the lever, the sharper the turn will be.

The machine can also be turned round within its ownlength. To do this, leave the drive in neutral (N). Operatethe lever to the left to turn anti-clockwise or right to turnclockwise. Avoid excessive or too rapid movement of thelever. Return the lever to the central position when themanoeuvre is complete.

Operating Procedures

! WARNINGDrive the machine smoothly. Avoid repeated start/stopor spin turn manoeuvres. Avoid unnecessary zig-zagdriving.8-1-2-2

Avoid exaggerated movements of the lever which couldcause the machine to go out of control through violentchanges of speed and/or direction.

When moving off from rest, gently move the Drive ControlLever from the neutral position. Gradually increase thelever movement until the desired speed is reached.

! WARNINGYou or others can be killed or injured if you suddenlychange from forward to reverse, or vice versa, whilsttravelling. The machine will immediately reversedirection without warning to others. Always follow therecommended procedure for changing betweenforward and reverse drive.3-1-2-5

When changing between forward and reverse drive,always bring the machine to rest first by progressivelymoving the Drive Control Lever into the neutral N position.

Always negotiate a turn by gentle, progressive use of thelever until the required rate of turn is achieved, andstraighten up in the same way afterwards. Never suddenlychange from a turn in one direction to a turn in theopposite direction.

When moving the machine, stay alert for obstructions andpossible hazards.

When travelling downhill, adjust the forward/reversesetting of the Drive Control Lever to achieve a suitable,steady speed.

When driving, if the engine gets overloaded and seemslikely to stall, ease off the Drive Control Lever to allow theengine speed to pick up again.

When overloading of the engine seems to be a recurringproblem, increase the setting of the Hand Throttle Controlif the engine is not already running at its preset maximumspeed. If the engine is already running at its maximumspeed, reduce the load by easing off the Drive ControlLever.

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53 53OPERATION

GETTING THE MACHINE MOVING(continued)

Getting Moving

1 Check your Seat and Seat Belt

Make sure that the seat is correctly adjusted. Makesure that your seat belt is correctly fastened andadjusted.

2 Start the Engine

Start the engine and set the Hand Throttle Control(see Starting the Engine).

1 Stop the Machine

Where possible, choose dry, level ground to stop themachine. Ease the Drive Control Lever to the neutralposition to bring the machine smoothly to rest.

! DANGERBefore lowering the attachments to the ground, makesure that the machine and the area around it are clearof other people. Anyone on or near the machine couldfall and be crushed by the attachments, or get caughtin the linkages.2-2-3-4

2 Lower the Attachments to the Ground

Operate the Control Levers to lower the attachmentsto the ground. Once they are on the ground, operatethem a little further so that they begin to take theweight of the machine.

3 Select Forward or Reverse to Move Off

a Check that the loader, backhoe and attachmentsare in the travel position (see Preparing theMachine For Travel).

b Release the Parking Brake (see Controls). c Make sure it is safe to move off, then slowly

operate the Drive Control Lever to forward F orreverse R as required. The machine will movesmoothly away.

3 Stop the Engine

Turn the Starter Key to the 'O' position. The machinebrakes are automatically applied when the enginestops.

4 Remove the Starter Key

If you are going to leave the machine, remove theStarter Key.

5 Switch off All Unnecessary Switches

! WARNINGDo not use the machine controls as handholds whenentering (or leaving) the machine. 2-2-1-4

6 Leave and Secure the Machine

Turn the seat to face the cab entrance before leaving(see Entering/Leaving the Cab). If you are leavingthe machine unattended, close and lock the door (iffitted).

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54 54OPERATION

USING THE ATTACHMENTS AND SITE SAFETY

This section explains some techniques for efficient andsafe use of the machine and its attachments. Attention isalso drawn to the various safety aspects of operating onsite. Read and understand this section before you startworking with the machine. Practise using the attachmentsuntil you are completely familiar with the controls and whatthey do.

Before you start using the machine, tell your work mateswhat you will be doing and where you will be working. On abusy site, use a signalman.

Remember that your machine is mobile. Wheneverpossible, manoeuvre your machine into a position whichcombines safety with efficiency. If you have to choose,remember that:

SAFETY MUST COME FIRST

Choose the correct attachment for the job. Do not use anoversize shovel for rocky material. It could overload thesystem and shorten service life.

! WARNINGWork sites can be hazardous. Inspect the site beforeworking on it. Look for potholes, weak ground, hiddenrocks etc. Check for utilities such as electric cables(overhead and underground), gas and water pipes etc.Mark the positions of the underground cables andpipes. Make sure that you have enough clearancebeneath overhead cables and structures.INT-2-2-1

! WARNINGBefore you start using the machine, inspect the jobsite. You could be killed or injured if the ground giveway under your machine or if piled material collapsesonto it. Check for potholes and hidden debris, logs,ironwork etc. Any of these could cause you to losecontrol of your machine.2-2-5-2

! CAUTIONYou and/or your company could be legally liable forany damage you may cause to public utilities. It is yourresponsibility to make sure that you know thelocations of all public utility cables or pipes on the sitewhich could be damaged by your machine.2-2-5-3

! WARNINGYou could be electrocuted or badly burned if you getthe machine or its attachments too close to electricalpower cables.

You are strongly advised to make sure that the safetyarrangements on site comply with the local laws andregulations concerning work near electric power lines.

Buried Electric Power CablesBefore you start using the machine, check with yourelectricity supplier if there are any buried power cableson the site.

Overhead Electric Power CablesThere is a minimum clearance required for workingbeneath overhead power cables. You must obtaindetails from your local electricity supplier.2-2-5-4

! WARNINGReworking Old Sites

There could be dangerous materials such as asbestos,poisonous chemicals or other harmful substancesburied on the site. If you uncover any containers oryou see any signs of toxic waste, stop the machineand advise the site manager immediately.2-2-5-5

! WARNINGWater Supplies and Drains

Before you start using the machine, check with yourlocal public water supplier if there are buried pipes anddrains on the site. If there are, obtain a map of theirlocations and follow the advice given by the watersupplier.

You are strongly advised to make sure that the safetyarrangements on site comply with the local laws andregulations concerning work near buried water pipesand drains.2-2-5-6

! WARNINGCommunications

Bad communications can cause accidents. Keeppeople around you informed of what you will be doing.If you will be working with other people, make sure anyhand signals that may be used are understood byeverybody. Work sites can be noisy, do not rely onspoken commands.INT-2-2-3

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55 55OPERATION

USING THE ATTACHMENTS AND SITE SAFETY(continued)

! WARNINGUnderground Gas Pipes

Before you start using the machine, check with yourlocal gas supplier if there are any buried gas pipes onthe site.

If there are buried gas pipes we recommend that youask the gas company for any specific advice regardingthe way you should work on the site.

Some modern gas pipes cannot be detected by metaldetectors, so it is essential that an accurate map ofburied gas pipes is obtained before any excavationwork commences.

Hand dig trial holes to obtain precise pipe locations.Any cast iron pipes found should be assumed to begas pipes until contrary evidence is obtained.

Older gas pipes can be damaged by heavy vehiclesdriving over the ground above them.

LEAKING GAS IS HIGHLY EXPLOSIVE.

If a gas leak is suspected, contact the local gascompany immediately and warn all personnel on thesite. Ban smoking, ensure that all naked lights areextinguished and switch off any engines which may berunning.

You are strongly advised to make sure that the safetyarrangements on site comply with the local laws andregulations concerning work near buried gas pipes.2-2-6-1/1

! WARNINGHillsides

Operating the machine on hillsides can be dangerousif proper precautions are not taken. Ground conditionscan be changed by rain, snow, ice etc. Check the sitecarefully.

Going uphill, reverse when unloaded or travel forwardswhen loaded. Going downhill, travel forwards whenunloaded or reverse when loaded.

Take special care when moving across a slope. If theslope is too steep your machine could roll over. If youmust drive across a slope, keep the attachments closeto the ground.3-1-1-4/1

! WARNINGBanks and Trenches

Banked material and trenches can collapse. Do notwork or drive too close to banks and trenches wherethere is danger of collapse.INT-2-2-5

! WARNINGSafety Barriers

Unguarded machines in public places can bedangerous. In public places, or where your visibility isreduced, place barriers around the work area to keeppeople away.INT-2-2-8

! WARNINGDo not dismount a moving machine.3-2-3-12

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56 56OPERATION

LOADER QUICKHITCH

Engaging the Shovel/Attachments

To engage a shovel or other attachment on the Quickhitch,do the following:

! WARNINGIf two people are doing this job, make sure that theperson working the controls is a competent operator. Ifthe wrong control lever is moved, or if the controls aremoved violently, the other person could be killed orinjured.2-2-6-5

1 Align the machine square to the shovel/attachment.

2 Lower the loader arm fully to bring the hitch plate Abelow the level of the lips on the shovel/attachment.Make sure levers X are moved fully out beyond thesides of the hitch plate.

3 Drive the machine slowly forward. Stop when the hitchplate A just touches the shovel/attachment.

4 Raise the loader arm and engage the hitch plate A inthe lips on the shovel/attachment. Stop the movementas soon as the plate is engaged.

5 Operate the Shovel Control Lever to fully roll back theshovel, to allow the Quickhitch to fully engage. Movethe lever back slightly so that the shovel is not at theend of its travel. This is to allow clearance for theQuickhitch push levers to operate.

6 Dismount from the machine or ask a second person tohelp.

7 Push levers X fully towards the middle of the hitchplate to engage the Quickhitch locking pins Y. Theywill lock into detents.

8 The shovel/attachment is now locked onto theQuickhitch.

9 If appropriate, connect the attachment tail hoses tothe loader arm auxil iary pipework (seeConnecting/Disconnecting Hydraulic Hoses inOPTIONAL ATTACHMENTS section). Theshovel/attachment is now ready for use.

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57 57OPERATION

LOADER QUICKHITCH(continued)

Disengaging the Shovel/Attachments

! WARNINGIf two people are doing this job, make sure that theperson working the controls is a competent operator. Ifthe wrong control lever is moved, or if the controls aremoved violently, the other person could be killed orinjured.2-2-6-5

1 Stop and park the machine on level ground.

2 Lower the shovel/attachment to the ground.

3 Stop the engine and relieve hydraulic circuit pressure(see Connecting/Disconnecting Hydraulic Hosesin OPTIONAL ATTACHMENTS section).

! DANGERDo not retract the locking pins when the loader arm israised, the bucket could fall and kill or seriously injuresomeone. Only retract the locking pins after the shovelhas been placed on the ground.4-2-2-1

4 Dismount from the machine or get someone else toperform Steps 5 and 6.

5 If appropriate, disconnect the attachment tail hosesfrom the loader arm pipework (seeConnecting/Disconnecting Hydraulic Hoses inOPTIONAL ATTACHMENTS section).

6 Pull levers X fully out beyond the sides of the hitchplate A to retract the Quickhitch locking pins Y.

7 Return to the cab seat or make sure your assistant iswell clear of the Quickhitch. Start the engine.

8 Operate the Shovel Control Lever to roll forward theshovel (see Loader Controls).

9 When the hitch plate A has disengaged from the lipson the shovel/attachment, reverse the machine clear.

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58 58OPERATION

WORKING WITH THE LOADER

! WARNINGYou or others can be killed or seriously injured if youoperate the control levers from outside the cab.Operate the control levers only when you are correctlyseated inside the cab.INT-2-1-3

Remember that you will be driving the machine while youare using the loader. Keep alert for bystanders andpossible hazards. Stay in the correct driving position. Keepyour seat belt fastened and correctly adjusted.

Keep the loader arm fully down when travelling. Thisincreases your visibility and makes the machine morestable.

! WARNINGWhen transporting a load on a slope, drive slowly andkeep the load uphill of the machine. This will increasestability.2-1-1-5

! WARNINGRollover

Should the machine start to roll over, you can becrushed if you try to leave the cab. If the machinestarts to roll over, DO NOT TRY TO JUMP FROM THECAB. STAY IN THE CAB, WITH YOUR SEAT BELTFASTENED.INT-2-1-12

Filling the Shovel

! WARNINGWhen loading with material from a high bank or pile,remove any overhang first. Watch out for slidingmaterial. If overhanging material falls, you and yourmachine could be buried.2-2-6-3

On hard surfaces, as the shovel enters the pile, start rollingback (crowding) the shovel while raising the loading arm atthe same time. This will sweep the shovel up the pile,gathering material as it goes.

Easing back the Drive Control Lever will give more powerto operate the shovel. Try to fill the shovel in one pass. Halffull shovels are less productive. When moving the load, rollthe shovel right back to prevent spillage.

When you are loading from a pile of loose material, start atthe bottom and follow up the face as shown at A. Approachthe pile with the shovel level and the loader arm fully down.In tightly packed material, start at the top and work down.

When removing material from a stockpile, start at ashovel's height from the base. Once the height of thestockpile has been reduced, begin loading from the base.

Loading a Truck

Put the truck(s) at an angle of about 45° to the pile, asshown at B. This cuts out unnecessary manoeuvring. Allowenough distance for the shovel to reach its unloadingheight while you are travelling, without slowing down.

Keep the wind on your back. This keeps dust away fromyou and your machine.

Move your machine as close as possible to the truckbefore unloading.

If the truck body is about as long as a shovel's width, tipthe load into the centre of the truck. If the truck is twoshovel-widths long or more, load the front of the truck first.

Do not dump the material in one sudden movement. Rollthe shovel forward in stages until it is empty. Use thecontrol lever to rock the shovel back and forth to loosenany sticking material.

Scraping and Cutting

If a deep cut is to be made, do it in steps of about 50 mm(2 in). With the loader arm fully down, adjust the shoveldump angle to give the desired depth of cut.

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59 59OPERATION

WORKING WITH THE BACKHOE

! WARNINGBefore you start using the backhoe, you must convertthe machine into a safe and stable working platform.See Preparing to Use the Backhoe (OPERATIONsection) for details.2-2-6-4/1

If you will be working with a labourer, make sure you bothunderstand what each other will be doing. Learn and usethe recognised signalling procedures. Do not rely onshouting - he will not hear you.

Make sure the correct bucket for the job is fitted.

Set the hand throttle control so that the engine speed isright for the job in hand.

Removing a Bucket

1 Set the backhoe straight behind the machine. Restthe bucket on level ground, with the bucket flat asshown. Block the bucket to prevent its movement.

! WARNINGStand clear and to one side of the bucket while youremove the pivot pins. With the pivot pins removed,the bucket could roll over.2-2-6-6

2 Unclip and remove the lynch pins A. Remove thepivot pins B.

3 Using the controls, carefully lift the dipper clear of thebucket.

Fitting a Bucket

Note: The JCB 1CX can accept 803 series and Kubotabuckets. However, because of the different geometry ofthese buckets, the auxiliary pipework must be removedfrom the boom before fitting, or damage to the pipeworkmay result.

Note: This job is easier done by two people - one tooperate the controls and one to line up the pivots.

1 Set the bucket flat on level ground as shown, using asuitable lifting device.

2 Reverse the machine to align the dipper end as closeas possible to the bucket hinge area.

! WARNINGIf two people are doing this job make sure that theperson working the controls is a competent operator. Ifthe wrong control lever is moved, or if the controls aremoved violently, the other person could be killed orinjured.2-2-6-5

3 Lower the stabiliser legs.

4 Carefully operate the controls to line up the holes inthe dipper and tipping link with the holes in the bucket.Install the pivot pins B and lynch pins A.

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60 60OPERATION

WORKING WITH THE BACKHOE(continued)

Preparing to Use the Backhoe

When choosing a digging position, avoid digging downhill ifpossible. Whenever possible, dump the load on the uphillside of the excavation. Both these precautions will help tokeep the machine stable.

1 When the machine is in the desired position on thesite, roll the loader shovel fully forward, then lower itto take the weight off the front tyres.

Note: On tarmac surfaces, do not roll the shovel fullyforward. Keep the bottom of the shovel flat on the ground.This will minimise damage to the surface.

2 Engage the parking brake

3 Lower the stabilisers to raise the rear tyres just clearof the ground. Adjust the stabiliser positions until themachine is level. In soft ground, put heavy duty planksbeneath the stabilisers. This will spread the weightand prevent sinking.

4 Facing the rear of the machine, disengage the boomand slew locks (see Boom and Slew Locks ).

5 Increase engine speed using the hand throttle leveruntil the green indicator light is illuminated (seeBackhoe Controls).

Digging

To start the dig, reach out with the boom and dipper andposition the bucket as shown at A.

Slowly close the bucket and at the same time bring thedipper in. Make sure the bucket stays at the same angle tothe ground while it travels. If necessary, at the same timeapply a downward pressure on the boom, to increase thedigging force on the bucket.

When the bucket is full, close it fully and at the same timemove the dipper out a little way as at B. This will keep soilfrom building up under the machine.

Swing the bucket towards the dump area C. Start dumpingas the bucket approaches the pile. Do not waste time bydumping too far from the excavation. Dump close to thestart dig position. Swing the bucket back to the excavationand start the next dig.

Note: Do not use the side of the excavation to stop thebucket. This could damage the machine.

Backfill the excavation by loading the bucket with soil fromthe pile. Do not push the soil with the side of the bucket.

4230-2

S203591

A

S203601

B

S203611

C






61 61OPERATION

WORKING WITH THE BACKHOE(continued)

Moving the Machine While Digging

! WARNINGWhen moving the machine downhill, make sure youare in the correct driving position. Keep theattachments low to the ground.2-2-6-8/1

To move the machine when digging, raise the backhoe,stabilisers and shovel and carefully drive the machine to itsnext position.

Digging Near Walls

! WARNINGWhen digging near a wall, take care not to underminethe foundations. The wall could collapse.2-2-7-1

Digging on Slopes

To dig a trench across a slope, use the stabilisers andloader shovel to level the machine. On steeper slopes, cuta level base to work from. Dump the trench material on theuphill side of the trench, far enough away to prevent itfalling back into the trench.

4230-1






62 62OPERATION

SIDESHIFTING THE BACKHOE

Note: Before sideshifting the backhoe, make sure that thekingpost rails are clear of debris.

1 Use the stabilisers to set the machine level andstable, with the kingpost vertical.

2 Rest the backhoe bucket on the ground as shown,straight behind the machine.

3 Fully lift knob C to release the hydraclamps.

4 Operate the boom up and down a few times to loosenthe kingpost on its rails.

5 Raise and slew the backhoe directly to one side of themachine. Slew to the left if you want to sideshift to theright. Slew to the right if you want to sideshift to theleft. Set the bucket on the ground, with the dipper at90° to the boom as shown.

6 Open the bucket. As the bucket opens, the kingpostwill be pushed across the back of the machine A. Ifthe kingpost sticks in mid-travel, raise or lower theboom slightly to keep the kingpost vertical to the railsB.

7 Once the kingpost is in the position you want, tightenthe hydraclamps by lowering knob C ful ly andoperating boom up for 2-3 seconds.

4230-1

203560

B

A

S202821

S202920

S202831

S203580

C

C






63 63OPERATION

OPERATING IN LOW TEMPERATURES

4230-2

In low temperature situations, take the followingprecautions. They will make for easier starting and preventpossible damage to your machine.

1 Use the Correct Viscosity Engine Lubricating Oil

See Fluids, Capacities and Lubricants inMAINTENANCE section.

2 Use a Low Temperature Diesel Fuel

If available. See Fuel System in MAINTENANCEsection.

3 Use the Correct Coolant Mixture

See Engine Cooling System in MAINTENANCEsection.

4 Keep the Battery at Full Charge

This helps to prevent freezing of the batteryelectrolyte.

5 Fill the Fuel Tank at the End of Each Work Period

This helps to prevent the formation of condensation inthe tank.

6 Protect the Machine When Not in Use

Park the machine inside a building or cover it with atarpaulin.

7 Install Cold Weather Starting Aids

In very low temperatures, i.e. below -18 °C (0 °F)additional starting aids may be needed. Examples arefuel, oil and coolant heaters and extra batteries. Askyour JCB distributor for advice.

Note: Do not connect two batteries in series to give 24volts for starting. This could burn out the engine glow plugsand starter motor.

! WARNINGDo not use ether or other starting fluids to assist coldstarting. Using these fluids may result in an explosioncausing possible injury and/or damage to the engine.3-2-1-9

8 Remove Snow from the Bonnet and RadiatorGrille

If the flow of cooling air is impeded, the engine couldoverheat.

9 Starting the Engine

Follow Steps 1 to 5 of Starting the Engine. Once theengine starts, increase the hand throttle settingimmediately.

! CAUTIONDo not attempt to operate the machine immediatelyafter starting in cold conditions, i.e. below -5°C (20°F).The machine may not respond properly to controlmovements. Allow at least 10 minutes warm up timewith the engine at half throttle. Operate the arm andshovel services to warm the hydraulic oil.3-1-1-5/1

OPERATING IN HIGH TEMPERATURES

In high temperature situations, take the followingprecautions to prevent possible damage to the machine.

1 Use the Correct Viscosity Engine Lubricating Oil

See Fluids, Capacities and Lubricants inMAINTENANCE section.

2 Use the Correct Coolant Mixture

See Engine Cooling System in MAINTENANCEsection.

3 Check the Coolant System Regularly

Keep the coolant at the correct level. Make sure thereare no leaks.

4 Keep the Radiator Clean

Regularly remove dirt and debris from the radiator andthe engine.

5 Check the Alternator Belt Tension Regularly

See Engine Alternator Belt in MAINTENANCEsection.

6 Check the Engine Air Filter Regularly






64 64OPERATION

TRANSPORTING THE MACHINE

4230-3

The safe transit of the load is the responsibility of thetransport contractor and driver. Any machine,attachments or parts that may move during transitmust be adequately secured.5-2-5-9

Note: Make sure that the transporting vehicle is suitable.See Static Dimensions in SPECIFICATIONS section forthe dimensions and weight of your machine.

Using a Truck

Provided a crane of adequate capacity is available, it ispermissible to lift a machine directly onto the back of asuitable truck. Refer to SPECIFICATION for machineweight and dimensions.

The machine incorporates two lifting points A at the frontand two B at the rear. It is necessary to use a lifting frameto avoid damage to the ROPS/FOPS structure. Consultyour JCB distributor for details.

! WARNINGYou can be injured if you use faulty lifting equipment.Make sure that lifting equipment is in good condition.Make sure that lifting tackle complies with all localregulations and is suitable for the job. Make sure thatlifting equipment is strong enough for the job.INT-1-3-7

Using a Trailer

! WARNINGBefore moving the machine onto the trailer, make surethat the trailer and ramp are free from oil, grease andice. Remove oil, grease and ice from the machinetyres. Make sure the machine will not foul on the rampangle. See Static Dimensions in SPECIFICATIONSsection for the minimum ground clearance of yourmachine.2-2-7-5/1

1 Position the Trailer

a If the machine is disabled it will be necessary toalign the trailer with the rear of the machine.

b For an operational machine any convenientposition will be suitable.

2 Block the Trailer Wheels and Position the Ramps

a Place blocks at the front and rear of the trailerwheels.

b Make sure the ramps are correctly in place andsecure.

3 Loading a Disabled Machine onto the Trailer

The trailer must be equipped with a winch to pull themachine aboard.

a Position the trailer as in 1a.b Connect the winch cable to the towing hitch on

the back of the machine.c Release the machine brakes (see Moving a

Disabled Machine). d Operate the winch and pull the machine onto the

trailer until the shovel/attachment is well insidethe back end of the trailer.

e Secure the cab (if door fitted).f Anchor the machine (see Transportation

Safety).

4 Loading a Serviceable Machine Onto the Trailer

a Set the loader shovel and backhoe as inPreparing For Travel.

b Carefully reverse the machine onto the trailer.c When the machine is safely in position, lower the

loader arm to its lowest position.d Switch off the engine.e Check that the overall height of the load is within

regulations. Adjust if necessary.f Secure the cab (if door fitted).g Cover the exhaust stack.h Anchor the machine (see Transportation

Safety).

S202891

S202900

A

B

A






65 65OPERATION

TRANSPORTING THE MACHINE(continued)

Transportation Safety

1 Position the machine

Make sure the machine is in the travelling positionwith the boom/slew lock fitted as shown at A.

Note: If for any reason the boom/slew lock cannot be fittedthen the backhoe must be positioned as shown at B withthe bucket securely lashed to the trailer bed. If no bucket isfitted then secure the dipper end to the trailer bed.

2 Anchor the Machine

Put blocks at the front and rear of all four tyres.Anchor the machine to the transporter with suitablechains over the front axle and over the rear frame.

3 Measure the Machine Height

Measure the maximum height of the machine from theground. Make sure the truck driver knows theclearance height before he drives away.

4230-2

S202881

MOVING A DISABLED MACHINE

It is only possible to tow or winch the JCB 1CX for shortdistances at slow speed in a straight line. This is becausethe steering function is inoperative unless the machine isbeing self-propelled.

If at all possible repair the disabled machine where itstands.

If the machine needs to be returned to the workshop forrepair, it must be winched onto a trailer or lifted onto atruck for transportation.

The procedure for preparing the machine for winching isvery complicated and must only be carried out by a JCBDistributor.

A

B






66 66OPERATION

EMERGENCY LOWER PROCEDURE

During normal operation, the engine must be runningbefore the loader arms can be raised or lowered.

If the engine fails whilst the loader arms are in the raisedposition, they may be lowered as follows:-

!! DANGERDo not stand underneath the raised load during thelowering procedure. Stand clear and to one side untilthe load has been safely lowered. Make sure that thearea is clear of other people before lowering the load.If you do not follow these precautions you or otherscould be killed or seriously injured.2-3-5-3

1 Make sure the area beneath the load is clear.

2 Machines up to serial no. 806864Remove the floor mat and the left hand floor plate (seeRemoving Floor Plates in Maintenance section).

Machines from serial no. 806865Remove the floor mat and the rear floor plate (seeRemoving Floor Plates in Maintenance section).

3 Move lever A slowly in the direction shown to lowerthe load.

4 As soon as the load is lowered close the valve byreturning the lever A to its previous position.

5 Replace the floor plate and mat.

4230-2

S263140

A

390180

A






71 71MAINTENANCE

LUBRICANTS - HEALTH AND SAFETY

Hygiene

JCB lubricants are not a health risk when used properly fortheir intended purposes.

However, excessive or prolonged skin contact can removethe natural fats from your skin, causing dryness andirritation.

Low viscosity oils are more likely to do this, so take specialcare when handling used oils, which might be diluted withfuel contamination.

Whenever you are handling oil products you shouldmaintain good standards of care and personal and planthygiene. For details of these precautions we advise you toread the relevant publications issued by your local healthauthority, plus the following.

Storage

Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Waste Disposal

All waste products should be disposed of in accordancewith all the relevant regulations.

The collection and disposal of used engine oil should be inaccordance with any local regulations. Never pour usedengine oil into sewers, drains or on the ground.

Handling

New Oil

There are no special precautions needed for the handlingor use of new oil, beside the normal care and hygienepractices.

Used Oil

Used engine crankcase lubricants contain harmfulcontaminants.

Here are precautions to protect your health when handlingused engine oil:

1 Avoid prolonged, excessive or repeated skin contactwith used engine oils.

2 Apply a barrier cream to the skin before handling usedengine oil.

3 Note the following when removing engine oil fromskin:

a Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

c Use special hand cleansers to help clean dirtyhands.

d Never use petrol, diesel fuel, or paraffin forwashing.

e Avoid skin contact with oil soaked clothing.

f Don't keep oily rags in pockets.

g Wash dirty clothing before re-use.

h Throw away oil-soaked shoes.

First Aid - Oil

EyesIn the case of eye contact, flush with water for 15 minutes.If irritation persists, get medical attention.

SwallowingIf oil is swallowed do not induce vomiting. Get medicaladvice.

SkinIn the case of excessive skin contact, wash with soap andwater.

Spillage

Absorb on sand or a locally approved brand of absorbentgranules. Scrape up and remove to a chemical disposalarea.

Fires

Extinguish with carbon dioxide, dry chemical or foam. Fire-fighters should use self-contained breathing apparatus.

4230-1

It is most important that you read and understand this information and the publications referred to. Make sure allyour colleagues who are concerned with lubricants read it too.






72 72MAINTENANCE

SERVICE REQUIREMENTS

Introduction

Your machine has been designed and built to givemaximum performance, economy and ease of use under awide variety of operating conditions. Prior to delivery, yourmachine was inspected both at the Factory and by yourDistributor to ensure that it reaches you in optimumcondition. To maintain this condition and ensure troublefree operation it is important that the routine services, asspecified in this Handbook, are carried out by an approvedJCB Distributor at the recommended intervals.

Maintenance

This section of the Handbook gives full details of theservice requirements necessary to maintain your JCBmachine at peak efficiency.

To further protect your machine's performance it isessential your JCB Distributor carries out an initial serviceand inspection when the machine is one month old orwhen it has completed 100 hours of operation (whicheveroccurs first). You should notify your Distributor in advanceto allow the necessary arrangements to be made.

It can be seen from the Service Schedules on the followingpages that many essential service checks should only becarried out by a JCB trained specialist. Only JCBDistributor Service Engineers have been trained by JCB tocarry out such specialist tasks, and only JCB DistributorService Engineers are equipped with the necessary specialtools and test equipment to perform such tasks, thoroughly,safely, accurately and efficiently.

JCB regularly updates its Distributors advising them of anyproduct developments, changes in specifications andprocedures. Therefore only a JCB Distributor is fully able tomaintain and service your machine.

At the rear of this Handbook is a Service Record Sheetwhich will enable you to plan your service requirementsand keep a service history record. This record sheet shouldbe dated, signed and stamped by your Distributor eachtime your machine is serviced.

Remember, if your machine has been correctly maintained,not only will it give you improved reliability but its resalevalue will be greatly enhanced.

Owner/Operator Support

JCB together with your Distributor wants you to becompletely satisfied with your new JCB machine. If you doencounter a problem however, you should contact yourDistributor's Service Department which is there to help you!

You will have been given the names of the relevant servicecontacts at your Distributor when the machine wasinstalled.

To get the most from your Distributor please help the staffto satisfy you by:

1 Giving your name, address and telephone number.

2 Quoting your machine model and serial number.

3 Date of purchase and hours of work.

4 Nature of the problem.

Remember, only your JCB Distributor has access to thevast resources available at JCB to help support you. Inaddition, your Distributor is able to offer a variety ofprogrammes covering Warranty, Fixed Price Servicing,Safety Inspections, including weight tests, covering bothlegal and insurance requirements:

Service/Maintenance Agreements

To help plan and spread the costs of maintaining yourmachine, we strongly recommend you take advantage ofthe many Service and Maintenance Agreements yourDistributor can offer. These can be tailor made to meetyour operating conditions, work schedule etc.

Please consult your JCB Distributor for details.

4230-1






73 73MAINTENANCE

A badly maintained machine is a danger to the operatorand the people working around him. Make sure that theregular maintenance and lubrication jobs listed in theservice schedules are done to keep the machine in a safeand efficient working condition.

! WARNINGMaintenance must be done by suitably qualifiedpersonnel. Before attempting any maintenance work,make sure the machine is safe. Park on level ground. Ifit is necessary to work with the loader arm raised, thenthe loader arm safety strut must be fitted, as shown inLoader Arm Safety Strut in MAINTENANCE section.2-3-1-1

Every 10 Operating Hours or Weeklywhichever occurs first (for the First 50Operating Hours only)

Check1 Tightness of wheel bolts

Every 10 Operating Hours or Daily whichever occurs first

Clean1 Machine generally, including cab interior

Check (Engine Stopped)1 Generally for damage, including ROPS/FOPS

structure2 Engine coolant level and condition3 Fuel system for leaks and contamination4 Hydraulic fluid level 5 Hydraulic system for leaks6 Engine oil level and condition 7 Engine generally for leaks8 Alternator belt tension9 Tyre pressures and condition10 Windscreen washer level (if fitted)11 Seat belt condition and security12 Slew oil level

Check (Engine Running)1 Warning lights extinguished2 Operation of all electrical equipment3 Exhaust for excessive smoke4 Operation of all hydraulic services

Grease1 Quickhitch pivot points 2 Loader arm pivot points 3 Backhoe pivot points

Apart from the daily jobs, the schedules are based onmachine running hours. Keep a regular check on thehourmeter readings. Do not use a machine which is due fora service. Make sure any defects found during the regularmaintenance checks are rectified immediately.

Every 50 Operating Hours or Weeklywhichever occurs first

Do the Daily jobs plus:

Check (Engine Stopped)1 Oil cooler connections2 Radiator hoses and condition3 Fuel filter (drain if necessary)

Clean1 Quickhitch square locking peg housings.

Every 100 Operating Hours or 2 Weeklywhichever occurs first

Do the Daily and 50 hour jobs plus:

Clean1 Battery terminals2 Air filter outer element when operating in dusty

conditions

Check (Engine Stopped)1 Condition of ram piston rods2 Hoses and pipework for chafing and damage3 Air cleaner hose security4 Wiring for chafing

Oil1 Backhoe lever clevises2 Door hinges (cabbed version)

4230-2

SERVICE SCHEDULES






74 74MAINTENANCE

SERVICE SCHEDULES(continued)

Every 250 Operating Hours or Monthlywhichever occurs first

Do the Daily to 100 hour jobs plus:

Clean1 Air cleaner dust valve2 Radiator matrix and oil cooler3 Hydraulic tank breather

Check (Engine stopped)1 Tightness of wheel bolts2 Engine and pump mounting bolts for tightness3 Radiator hose condition4 Motor mounting bolts for tightness5 Hub mounting bolts for tightness6 Drive chain case oil levels

Check (Engine running)1 Idling speed*2 Maximum governed speed*3 Exhaust system security4 Exhaust for excessive smoke5 Throttle system and control pedal6 Operation of all hydraulic services7 Operation of control isolation8 Parking brake operation9 Operation of electrical system10 Operation of attachments11 Check for fluid leaks (e.g. coolant, engine oil,

hydraulic oil, etc.

Change (Engine Stopped)1 Engine oil and filter (up to machine no. 807552)2 Fuel filter element3 Hydraulic fluid filter

Every 500 Operating Hours or 6 Monthlywhichever occurs first


Clean1 Cab heater filter (if fitted)

Check (Engine Stopped)1 Pivot pins and bushes2 Battery charge and condition3 Battery electrolyte level (if applicable)

Change1 Engine oil and filter (from machine no. 807553)2 Air filter outer element (see note 2)

Every 1000 Operating Hours or Yearlywhichever occurs first


Check (Engine Stopped)1 Tighten cylinder head bolts*2 Drive chain tension*3 Valve clearances*

Check (Engine Running)1 M.R.V. pressure*2 A.R.V. pressure*3 Transmission stall pressure*

Change1 Air filter inner element2 Alternator belt

Every 2000 Operating Hours or 2 Yearlywhichever occurs first


Change1 Hydraulic fluid sample/change (clean suction strainer)*2 Engine coolant3 Drive chain case oil4 Engine breather (from machine no. 807553)*

Note 1: We recommend that service procedures markedby an * be carried out by a recognised JCB distributor.

Note 2: Air Cleaner Outer Element should be changedevery 100 hours if machine is working in dusty conditions.

4230-6






75 75MAINTENANCE

CLEANING THE MACHINE

Clean the machine using water and/or steam. Payparticular attention to the underside. Do not allow mud tobuild up. Make sure the radiator grille is not clogged up.Remove debris from the kingpost mounting rails.

Inspect steelwork for damage. Note damaged paintworkfor future repair.

Make sure all pivot pins are correctly in place and securedby their locking devices.

Ensure that the steps and handrails are undamaged andsecure.

Check for broken or cracked window glass. Replacedamaged items.

Checking the ROPS/FOPS Structure

! WARNINGThe machine is fitted with a Roll Over ProtectionStructure (ROPS) and a Falling Objects ProtectionStructure (FOPS). You could be killed or seriouslyinjured if you operate the machine with a damaged ormissing ROPS/FOPS. If the ROPS/FOPS has been in anaccident, do not use the machine until the structurehas been renewed. Modifications and repairs that arenot approved by the manufacturer may be dangerousand will invalidate the ROPS/FOPS certification.INT-2-1-9/3

1 Check the structure for damage.

2 If necessary, have the structure repaired by suitablyqualified personnel (consult your JCB distributor).

3 If the damage is severe it will be necessary to obtain acomplete new structure.

Check all bucket teeth for damage and security.

Check all lamp lenses for damage.

Inspect the tyres for damage and penetration by sharpobjects.

Check that all safety decals are in place and undamaged,fit new decals where necessary (see Safety Decals inINTRODUCTION) .

4230-1

CHECKING FOR DAMAGE

ROPS/FOPS STRUCTURE






76 76MAINTENANCE

LOADER ARM SAFETY STRUT

Installing the Safety Strut

! WARNINGRaised loader arms can drop suddenly and causeserious injury. Before working under raised loaderarms, fit the loader arm safety strut.2-1-1-6

! WARNINGYou could be killed or seriously injured if the loadercontrol is accidentally operated. Make sure that no-onegoes near the machine whilst you fit the safety strut.16-3-1-5

1 Empty the shovel or attachment, if appropriate, andraise the loader arm enough to fit the safety strut.

2 Stop the engine.

3 Fit the strut:

a Remove the strut from its stowage position C.b Place the strut around the lift ram.c Secure the strut A into position using strap B.

4 Start the engine.

5 Slowly lower the loader arm onto the safety strut. Stopthe movement immediately the weight of the arm issupported by the strut.

Note: Extreme care must be taken when lowering theloader arm onto the safety strut. 'Feather' the lever to lowerthe loader arm slowly.

Removing the Safety Strut

! WARNINGYou could be killed or injured if the loader control isaccidentally operated. Make sure no-one comes nearthe machine while you remove the safety strut.2-3-1-3

1 Make sure that the drive control is in the neutral (rest)position.

2 Raise the loader arm to take the weight off the safetystrut A. Stop the engine.

3 Remove the strut:

a Release securing strap B.b Remove the safety strut from the lift ram.c Return the safety strut to its stowage position C.

4230-1

S202720S203851

C

A

B






77 77MAINTENANCE

ENGINE COMPARTMENT ACCESS

! CAUTIONThe engine has exposed rotating parts. Do not openthe engine cover while the engine is running. Do notuse the machine with the cover open.INT-2-1-6/1

! CAUTIONDo not use the machine with the engine exposed.5-3-1-6

Opening and Closing the Bonnet

To release the bonnet, insert key J into the bonnet lockand turn 90° clockwise.

Open the bonnet until the latch is engaged.

To close the bonnet, release the latch and lower thebonnet.

To lock the bonnet, insert key J into the bonnet lock andturn 90° anticlockwise.

To carry out various servicing procedures, you mustremove some of the floor plates.

1 Remove the two bolts B at each side which hold thefloor mat in position.

2 Carefully feed the mat out from the left hand side ofthe cab (the mat is split at the right hand side to makethis easier).

3 Remove the bolts holding the required section of floorplate.

Removing and Fitting a Side Panel

! WARNINGDo not remove the engine side panel while the engineis running.2-3-1-5

Note: It is easier to remove the panel either with theshovel resting on the ground or with the arms fully raised(See Loader Arm Safety Strut ).

1 Stop the engine and remove the starter key.

2 Raise the bonnet. (See Opening and Closing theBonnet ).

3 Remove the side panel by unscrewing fastener A andlifting the side panel upwards and outwards.

4 To fit the side panel, carefully slot the side panel intoposition, then tighten fastener A hand tight. Lower andlock the bonnet. (See Opening and Closing theBonnet ).

4230-2

REMOVING FLOOR PLATES

S203571 S203781

S203951

BB

J

A






78 78MAINTENANCE

SEAT BELT

Checking Seat Belt Condition andSecurity

! WARNINGA JCB approved seat belt is fitted to your machine.Replace it with a new one if it is damaged, if the fabricis worn, or if the machine has been in an accident. Fit anew seat belt every three years regardless ofcondition.2-3-1-8/1

! WARNINGYou will be working close into the machine for thesejobs. Lower the attachments if possible. Remove thestarter key and disconnect the battery. This willprevent the engine being started. Make sure theparking brake is engaged.

Block all four wheels before getting under themachine.2-3-2-1

The machine must be greased regularly to keep it workingefficiently. Regular greasing will also increase themachine's working life.

Grease should be applied with a grease gun, normally twostrokes of the gun should be sufficient.

Stop the greasing procedure when fresh grease appears atthe joint. Use the recommended grease. (See ServiceCapacities and Lubricants.)

In the following il lustrations, the grease points arenumbered. Count off the grease points as you applygrease to each one. Refit the dust caps after greasing.

When checking the seat belt, look for signs of fraying andstretching. Make sure the stitching is not loose ordamaged. Make sure the buckle assembly is workingcorrectly and not damaged. Fit a new seat belt every threeyears.

Make sure the belt mounting bolts are undamaged,correctly fitted and tightened.

Quickhitch Pivot Points

Lower the loader arm as far as it will go. Tilt the Quickhitchfully forward to facilitate access to the central pivot pingrease points. Switch off the engine and ensure itcannot be started while you are doing this job.

Total of 6 grease points.

4230-2

GREASING (10 HOURS)

203960

21

3

5

64






79 79MAINTENANCE

GREASING (10 HOURS)(continued)

! WARNINGRaised loader arms can drop suddenly and causeserious injury. Before working under raised loaderarms, fit the loader arm safety strut.2-1-1-6

Loader Arm Pivot Points

Switch off the engine and ensure it cannot be started whileyou are doing this job.

For each grease point shown there is another on the otherside of the machine.

Note: Grease point 11 is at the lift ram/chassis pivot.

11 grease points each side -Total 22 grease points.

4230-1

S203481

)

12

7

3

9

5

4

6 !

8






80 80MAINTENANCE

GREASING (10 HOURS)(continued)

Backhoe

Switch off the engine and ensure it cannot be startedwhile you are doing this job.

Note: Grease point 5 is at dipper ram dump end.Grease point 14 is on end of dipper.

Total 14 grease points.

Note: Lubricate the kingpost mounting rails and stabiliserlegs with diesel oil or Waxoyl.

4230-1

S203491

12

3

£

4

6

7

5

8

9

!

)

@ $






81 81MAINTENANCE

LUBRICATION

The following points should be lightly lubricated withengine oil every 100 operating hours.

!! WARNINGYou will be working close into the machine for thesejobs. Lower the attachments if possible. Remove thestarter key and disconnect the battery. This willprevent the engine being started. Make sure theparking brake is engaged.

Block all four wheels before getting under themachine.2-3-2-1

1 Park the machine on level ground and stop theengine.

2 To machine no 807225: Check that the slew oil levelis up to the mark on the breather C.From machine no. 807226 (not fitted with breather C):Remove plug D and check that oil is visible on theplug spigot.

3 If the level is low, remove plug D (if not alreadyremoved) and fill with new oil until oil runs from thehole. See Fluids, Lubricants and Capacities forrecommended oil grade.

4 Refit plug D. To machine no 807225 only: Fill through breather Cto the level mark.

5 Operate the slew service fully in each direction fivetimes.

6 Remove plug D and re-check oil level. If level is low,repeat steps 3 to 5 until all air is expelled.

Oiling Control Levers

Oil the clevis A at the bottom of each backhoe controllever.

Oiling Door Hinges (cabbed machines)

Oil the door hinges B sparingly.

4230-2

CHECKING SLEW OIL LEVEL

S203540202740

203940

A

B

B

C

D






82 82MAINTENANCE

ENGINE AIR FILTER

Changing the Elements

! CAUTIONThe outer element must be renewed immediately if thewarning light on the instrument panel illuminates.2-3-3-1

! CAUTIONDo not run the engine when the outer element hasbeen removed.16-3-3-1

! CAUTIONThe inner element of the engine air filter must bereplaced with a new one. Do not attempt to clean orwash the old element.16-3-4-1

1 Stop the engine.

2 Gain access to the engine compartment by openingthe bonnet. (See Engine Compartment Access.)

3 If changing the inner element, disconnect the filterinduction hose A. Cover the end of the hose toprevent rain and dirt from getting into the engine.

4 Unscrew wingnut H. Remove the outer element G.Take care not to tap or knock the element.

5 If required, unscrew nut F and remove inner elementE.

6 Clean inside the canister C and dust valve D.

7 Test the seating of seals B and J:a Smear the seals on the new elements with

grease.b Insert the new elements in canister C.c Remove the elements and check for witness

marks on the inside base of the canister.

8 If the seals are secure, re-insert the new innerelement and tighten nut F.

9 Insert the new outer element and tighten nut wing H.

10 Refit the induction hose A (if disconnected). Makesure that the wire to the Air Filter Blocked switch isattached to the spade connector.

Note: Do not run the engine with the dust valve Dremoved.

Note: In dusty conditions, the outer element can becleaned by blowing through in the reverse direction withclean dry compressed air. If the element is damaged, itmust be replaced. A new inner element must be fitted atleast every third time the outer element is changed. As areminder, mark the inner element with a felt tipped peneach time the outer element is changed.

4230-1

202760

B

A

J

F

E

G

HD

C






83 83MAINTENANCE

ENGINE OIL AND FILTER

Checking the Oil Level

!! WARNINGHot oil and engine components can burn you. Makesure the engine is cool before doing this job.2-3-3-2

1 Park the machine on level ground and lower theattachments to the ground.

2 Stop the engine and remove the starter key.

3 Raise the bonnet (see Engine CompartmentAccess).

4 Check that the oil level is within the marked area onthe dipstick A.

5 If necessary, add the recommended oil through thefi l ler point B. (See Fluids, Capacities andLubricants.)

6 Make sure the filler cap and the dipstick are secure.

7 Close the bonnet.

Changing the Oil and Filter

!! WARNINGHot oil and engine components can burn you. Makesure the engine is cool before doing this job.2-3-3-2

!! WARNINGOil is toxic. If you swallow any oil, do not inducevomiting, seek medical advice. Used engine oilcontains harmful contaminants which can cause skincancer. Do not handle used engine oil more thannecessary. Always use barrier cream or wear gloves toprevent skin contact. Wash skin contaminated with oilthoroughly in warm soapy water. Do not use petrol,diesel fuel or paraffin to clean your skin.INT-3-2-3

1 Do Steps 1 to 3 of Checking the Oil Level

2 Remove the left hand side panel (see EngineCompartment Access ).

3 Remove blanking plate X from underneath the front ofthe machine on the right hand side and pull out the oildrain hose.

4 Place a suitable container beneath the machine tocatch the oil.

cont.

4230-3

385360 S262150

XC

B

A






84 84MAINTENANCE

ENGINE OIL AND FILTER(continued)

Changing the Oil and Filter (continued)

!! WARNINGOil will gush from the hole when the drain plug isremoved. Hot oil and engine components can burnyou. Keep to one side when you remove the plug.13-3-1-15

5 Remove the drain plug C from the end of the hose toallow oil to flow into the container.

6 After emptying the sump, replace the drain plug C.Position the drain hose back inside the chassis andreplace blanking plate X.

7 Change the filter:a Unscrew the filter canister D; remember that it will

be full of oil.b Clean the filter head E.c Add clean engine lubricating oil to the new filter

canister. Allow enough time for the oil to passthrough the filter element.

d Smear the seal F on the new filter with oil. Screwin the new filter canister - hand tight only.

8 Fill the engine to the max mark on the dipstick withnew oil through the filler. See Fluids, Lubricants, andCapacities for recommended oil grades. Wipe off anyspilt oil. Check for leaks. Make sure the filler cap iscorrectly fitted.

9 Make sure the engine will not start by removing theengine shut-off solenoid (ESOS) fuse (see Fuses).Turn the engine using the starter key until the oilpressure warning light is extinguished.

10 Refit the ESOS fuse and start the engine. Check forleaks. When the engine has cooled, check the oil leveland, if necessary, top up with clean engine oil.

11 Refit the left hand side panel and lower the bonnet.

4230-3

385370

D

E

S262150

XC

F






85 85MAINTENANCE

ENGINE COOLING SYSTEM

Coolant Mixtures

The protection provided by JCB Four Seasons Anti-freeze& Summer Coolant is shown below. If any other anti-freezeis used, refer to the manufacturer’s instructions and ensurethat a corrosion inhibitor is included.

DO NOT use solutions of more than 50% or damage to theengine may occur.

Solution Maintains circulation Protects againstdown to damage down todeg C deg F deg C deg F

50% -33 -27 -45 -49

The strength of the anti-freeze solution must be checked atleast once a year, preferably at the beginning of the coldperiod.

It is an advantage to leave the anti-freeze in all the yearround as it gives continued protection against corrosion.Always renew the anti-freeze every two years.

A 50% anti-freeze mixture must be used even if frostprotection is not needed. This gives protection againstcorrosion and raises the coolant’s boiling point.

! WARNINGAntifreeze can be harmful. Obey the manufacturer'sinstructions when handling neat or diluted antifreeze.7-3-4-4

Checking the Coolant Level

! WARNINGThe cooling system is pressurised when the coolant ishot. Hot coolant will burn you. Make sure the engine iscool before checking the coolant level or draining thesystem.2-3-3-3

1 Park the machine on level ground. Stop the engineand let it cool down.

2 Raise the bonnet (see Engine CompartmentAccess). Check that the coolant level in theexpansion bottle is 2/3 full.

Note: If the level in the expansion bottle is low, thencontinue with steps 3 to 6.

3 Top up the expansion bottle through the filler cap A.The bottle should be 2/3 full.

4 Refit the filler cap and make sure it is tight.

5 If there is little or no coolant in the expansion bottle,remove filler cap B and top up the level to just belowthe filler neck. Refit the filler cap and make sure it istight

6 Run the engine for a while to raise the coolant toworking temperature and pressure. Stop the engineand check for leaks.

4230-2

S262140

B

S263130

A






86 86MAINTENANCE

ENGINE COOLING SYSTEM(continued)

Changing the Coolant

1 Park the machine on level ground. Stop the engineand let it cool down. Open the bonnet (see EngineCompartment Access).

2 Carefully loosen filler cap A just enough to let anypressure escape. Remove the cap when all pressureis released.

3 Remove the bottom hose from the lower box of theradiator.

4 Unscrew the cylinder block drain tap C.

5 Flush the system by pouring clean water into filler capA.

6 Clean and refit bottom hose and tighten cylinder blockdrain tap C.

7 Fill the system to just below the filler neck using thenecessary anti-freeze solution. (See CoolantMixtures.)

8 Refit the filler cap A.

9 Top up the expansion bottle through the filler cap B.The bottle should be 2/3 full.

10 Run the engine for a while to raise the coolant toworking temperature and pressure. Stop the engineand check for leaks. Check the coolant level and topup if necessary.

Cleaning the Coolant Radiator

1 Park the machine on level ground within reach of acompressed air line. Stop the engine and remove thekey. Open the bonnet and remove outer radiator grilleby unscrewing fastener D and lifting off the grille.

2 After allowing the engine to cool down usecompressed air to remove debris from the radiator E.

3 Use a brush to remove any further debris.

4 Inspect the radiator for damage.

5 Refit the outer radiator grille, screwing fastener Dhand tight, and close the bonnet.

4230-1

S202791

S203521

D

E

S255870

C

S262140

A






87 87MAINTENANCE

ENGINE ALTERNATOR BELT

Checking the Alternator Belt Tension

The upper illustration applies to machines up to serial no.807552. The lower illustration applies to machines fromserial no. 807553.

1 Park the machine on level ground.

2 Stop the engine.

3 Open the bonnet and remove the left hand engineside panel (see Engine Compartment Access ).

4 When correctly set the belt has approximately 10 mmof slack at point X.

5 If the belt requires adjusting proceed as belowAdjusting the Alternator Belt.

!! WARNINGMake sure the engine cannot be started. Disconnectthe battery before doing this job.2-3-3-5

Adjusting the Alternator Belt

1 Loosen bolts A and B which secure the alternator.

2 Reposition the alternator until belt deflection at pointX is approximately 10 mm (3/8 in).

! CAUTIONAny leverage required to position the alternator mustbe applied at the drive end bracket only, using awooden lever.8-3-2-1

3 Tighten bolts A and B.

4 Refit the left hand engine side panel and close thebonnet.

4230-2

S255830

B

X

A

385380

B

X

A






88 88MAINTENANCE

DRIVE CHAIN LUBRICATION

The final drive to the wheels is by chains. A chain casingon each side of the machine houses two chains, one to thefront wheel and one to the rear wheel. The chains run in anoil bath.

Checking the Oil Levels

1 Park the machine on level ground.

2 Stop the engine.

3 On the left side of the machine, remove inspectionplug A and check that the oil level is up to the bottomof the aperture.

4 If necessary, top up through the aperture using therecommended oil. (See Fluids, Capacities andLubricants.) Wipe up any oil spillage.

5 Check that the washer on plug A is undamaged.Renew if necessary.

6 Clean plug A and its aperture before refitting. Do notovertighten or you could strip the threads in thehousing.

7 Repeat steps 3 to 6 on the right side of the machine.

4230-1

Note: This diagram shows the location of the chain casing plugs on the left side of the machine. The right side casing is amirror image of the left side casing.

203750

A






89 89MAINTENANCE

FUEL SYSTEM

Types of Fuel

Use good quality diesel fuel to get the correct power andperformance from your engine. The recommended fuelspecification for JCB engines is given below.

Cetane Number: 45 (minimum)Viscosity: 2.5/4.5 Centistokes at 40°C (104°F)Density: 0.835/0.855 kg/litre

(0.872/0.904 lb/pint)Sulphur: 0.5% of mass (maximum)Distillation: 85% at 350 °C (662 °F)

Cetane Number

Indicates ignition performance. Fuel with a low cetanenumber can cause cold start problems and affectcombustion.

Viscosity

Is the resistance to flow. If this is outside limits, the engineperformance can be affected.

Density

Lower density will reduce engine power. Higher density willincrease both engine power and exhaust smoke.

Sulphur

High sulphur content can cause engine wear. (High sulphurfuel is not normally found in North America, Europe orAustralia.) If you have to use high sulphur fuel you mustalso use a highly alkaline engine lubricating oil; or changethe normal oil more frequently.

Low sulphur fuels are commonly used throughout theworld. These fuels contain fewer lubrication additives. Thefuel injection pump is lubricated by the fuel; therefore usinglow sulphur fuel may, in the long term, affect the pump.

If you have to use low sulphur fuel you are advised to usea lubrication additive as recommended by your fuelsupplier.

Distillation

This indicates the mixture of different hydrocarbons in thefuel. A high ratio of lightweight hydrocarbons can affect thecombustion characteristics.

Fuel Standards

Consult your fuel supplier or JCB distributor about thesuitability of any fuel you are unsure of.

Low Temperature Fuels

Special winter fuels may be available for engine operationat temperatures below 0 °C (32 °F). These fuels have alower viscosity. They also limit wax formation in the fuel atlow temperatures. (Wax forming in the fuel can stop thefuel flowing through the filter).

Flow improvers may also be available. These can beadded to the fuel to reduce wax formation.

Petrol

! WARNINGDo not use petrol in this engine. Do not mix petrol withthe diesel fuel. In storage tanks the petrol could rise tothe top and form flammable vapours.INT-3-1-6

Advice

If you have to use non-standard fuels, contact your JCBdistributor for advice on engine adjustments and oil changeperiods.

Fatty Acid Methyl Ester Fuels as areplacement for Diesel Fuels

Fuel resources such as Rape Methyl Ester and SoybeanMethyl Ester, collectively known as Fatty Acid MethylEsters, are being used as alternatives and extenders formineral oil.

Fatty Acid Methyl Esters must conform to certain standardsto be of acceptable quality, just as mineral oils do atpresent.

Consult your JCB distributor for advice about the use ofFatty Acid Methyl Ester fuels as improper application mayimpair engine performance.

Filling the Tank

! WARNINGDiesel fuel is flammable; keep naked flames away fromthe machine. Do not smoke while refuelling themachine or working on the engine. Do not refuel withthe engine running. There could be a fire and injury ifyou do not follow these precautions.INT-3-2-2

At the end of every working day, fill the tank with thecorrect type of fuel. This will prevent condensation fromdeveloping in the fuel tank overnight.

We recommend that, if possible, you lock the fuel cap toprevent theft and tampering.

4230-2






90 90MAINTENANCE

FUEL SYSTEM(continued)

Draining the Fuel Filter

The fuel filter is located at the front left hand side of theengine compartment.

1 Stop the engine.

2 Open the bonnet.

3 Drain off any water in the bowl B by opening tap A.

4 Re-tighten tap A.

5 If there is sediment in the bowl B change the elementF. See Changing the Fuel Filter Element.

Changing the Fuel Filter Element

1 Stop the engine.

2 Open the bonnet.

3 Place a receptacle under the filter to catch any fuel.Slacken tap A.

4 Support the bowl B and unscrew bolt C. Remove thebolt C, remove and discard washer D and 'O' ring E.

5 Remove filter element F, bowl B and base G as a unit.

6 Discard 'O' ring H.

7 Separate element F, bowl B and base G.

8 Remove and discard seals J (3 off), discard 'O' ring L.

9 Lubricate all seals and 'O' rings with clean fuel oil.

10 Fit new seals J (3 off) to base G, bowl B and elementF, fit 'O' ring H to the centre of the element F.

11 Fit element F, bowl B, base G, to the head K.

12 Insert centre bolt C after fitting new washer D and 'O'ring E. Tighten the bolt C carefully by hand to ensurethat all seals are correctly seated. Fit new 'O' ring L totap A and insert tap into base G.

13 Tighten bolt C to 8-11 Nm (6-8 lbf ft, 0.8-1.1 kgf m).

continued

4230-2

S255820

C

K

D

HJ

F

J

B

J

G

AL

E

M






90A 90AMAINTENANCE

FUEL SYSTEM(continued)

Changing the Fuel Filter Element (cont’d)

14 Prime the Filter.

Early Machines

Slacken bleed screw M and operate the lift priminglever N until fuel spurts from the loosened screw withno entrapped air.

Note: If no fuel is moved when the fuel lift pumppriming lever N is operated, then the pump diaphragmmay have rested in the ‘maximum lift’ position. Tomove the diaphragm, use the starter key to turn theengine, then try the priming lever again.

Later Machines

Slacken bleed screw M and operate the priming pumpP by squeezing the body until fuel spurts from theloosened screw with no entrapped air.

15 Tighten the bleed screw and check the filter for leaks.Tighten connections or change seals as required.

4230-1

S255860

N

329160

P






91 91MAINTENANCE

HYDRAULIC SYSTEM

! WARNINGFine jets of hydraulic fluid at high pressure canpenetrate the skin. Do not use your fingers to checkfor hydraulic fluid leaks. Do not put your face close tosuspected leaks. Hold a piece of cardboard close tosuspected leaks and then inspect the cardboard forsigns of hydraulic fluid. If hydraulic fluid penetratesyour skin, get medical help immediately.INT-3-1-10/1

Checking the Fluid Level

1 Position the backhoe in the site travel position (seePreparing the Machine for Travel in theOPERATION section) and stop the engine.

2 Look at the fluid level in the sight glass A. The levelshould be visible in the sight glass.

3 If the level needs topping up, wait five minutes,remove the battery compartment cover, loosen thehydraulic top-up filler cap B and allow all pressure todissipate.

4 Open filler cap B and top up with the recommendedfluid. (See Fluids, Capacities and Lubricants.)

! CAUTIONIf the fluid is cloudy, water or air has entered thesystem. This could damage the hydraulic pump.Contact your JCB distributor.7-3-6-1

Changing the Filter

1 Stop the engine and wait for 5 minutes.

2 Loosen the hydraulic tank filler cap B and allow allpressure to dissipate. Remove the filler cap.

3 Unscrew the old filter canister C, using a chainwrench if necessary, and discard.

4 Lubricate seal D on the new filter canister with cleanengine oil.

5 Screw on the new filter canister hand tight only.

Note: Machines fitted with the High-Flow hydraulic systemhave a second filter E which must also be changed. Thetwo filter canisters, although visually similar, are differentand must not be mixed.

6 Add engine oil through filler point B. (See Fluids,Capacities and Lubricants).

7 Refit cap B, run the engine for a few minutes, then re-check the fluid level.

4230-2

S203771A

C B

D

203790

E

218730






92 92MAINTENANCE

BATTERY

Safety

! WARNINGBatteries give off an explosive gas. Do not smokewhen handling or working on the battery. Keep thebattery away from sparks and flames.

Battery electrolyte contains sulphuric acid. It can burnyou if it touches your skin or eyes. Wear goggles.Handle the battery carefully to prevent spillage. Keepmetallic items (watches, rings, zips etc) away from thebattery terminals. Such items could short the terminalsand burn you.

Set all switches in the cab to OFF beforedisconnecting and connecting the battery. Whendisconnecting the battery, take off the earth (-) leadfirst.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a wellventilated area. Switch the charging circuit off beforeconnecting or disconnecting the battery. When youhave installed the battery in the machine, wait fiveminutes before connecting it up.5-3-4-3

DO THE FOLLOWING FIRST AID, IFELECTROLYTE:

GETS INTO YOUR EYES

Flush with water for 15 minutes, get medical helpimmediately.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water ormilk. Then drink milk of magnesia, beaten egg or vegetableoil.

GETS ONTO YOUR SKIN

Flush with clean water, remove affected clothing.

! CAUTIONDo not disconnect the battery while the engine isrunning, otherwise the electrical circuits may bedamaged.INT-3-1-14

! WARNINGBattery

A battery with frozen electrolyte can explode if it isused or charged. Do not use a machine with a frozenbattery. To help prevent the battery from freezing, keepthe battery fully charged.INT-3-1-7

! WARNINGElectrolyte

Battery electrolyte is toxic and corrosive. Do notbreathe the gasses given off by the battery. Keep theelectrolyte away from your clothes, skin, mouth andeyes. Wear safety glasses. See Battery inMAINTENANCE section for First Aid Treatment.INT-3-2-1/2

! WARNINGBattery Terminals

The machine is negatively earthed. Always connect thenegative pole of the battery to earth.

When connecting the battery, connect the earth (-) leadlast.

When disconnecting the battery, disconnect the earth(-) lead first.INT-3-1-9

! CAUTIONDamaged or spent batteries and any residue from firesor spillage should be put in a closed acid proofreceptacle and must be disposed of in accordancewith local environmental waste regulations.INT-3-1-12

! WARNINGKeep metal watch straps, and any metal fasteners onyour clothes, clear of the positive (+) battery terminal.Such items can short between the terminal and nearbymetal work. If this happens you can get burned.5-2-2-4

! WARNINGUnderstand the electrical circuit before connecting ordisconnecting an electrical component. A wrongconnection can cause injury and/or damage.INT-3-1-4

4230-3






93 93MAINTENANCE

BATTERY(continued)

Checking the Electrolyte Level

Maintenance free batteries used in normal temperatureclimate applications should not need topping up. However,in certain conditions (such as prolonged operation attropical temperatures or if the alternator overcharges) theelectrolyte level should be checked as described below.

The battery is mounted in a compartment on the right handside, above the rear wheel.

1 Stop the engine.

2 Remove the battery cover A.

! WARNINGDo not top up the battery with acid. The electrolytecould boil out and burn you.2-3-4-6

3 Remove battery cell cover(s) B. Make sure the level ineach cell is 6 mm (1/4 in) above the plates. Ifnecessary, top up with distilled water. Refit battery cellcover(s) B.

4 Refit the battery cover and secure.

4230-2

174421

B

Warning Symbols

The following warning symbols may be found on thebattery

Symbol Meaning

Keep away from children.

Shield eyes.

No smoking, no naked flames,no sparks.

Explosive gas.

Battery acid.

Note operating instructions.

A289230

A289260

A289280

A289250

A289240

A289270

203500

A






94 94MAINTENANCE

ELECTRICAL SYSTEM

Fuses

The electrical circuits are protected by fuses. The fusesare located behind panel H.

Fuse Circuits up to machine no. 752370 (Figure X)A1 Park BrakeA2 Auxiliary HydraulicsA3 High-flow HydraulicsA4 InstrumentationA5 Front / Rear HornA6 Hazard IndicatorsA7 Direction IndicatorsA8 Engine Shut-off SolenoidA9 Front Wash/wipe, Rear WiperA10 Heater MotorB1 Dip BeamB2 L.H. Side LightsB3 R.H. Side LightsB4 Front Work LightsB5 Rear Work LightsB6 Reverse Alarm, Brake LightsB7 Hand Held Attachments, Float HydraulicsB8 Face Level FanB9 Junction BoxB10 Beacon, Interior Light

Fuse Circuits from machine no. 752371 (Figure X)A1 Park BrakeA2 Auxiliary HydraulicsA3 High-flow HydraulicsA4 InstrumentationA5 Engine Shut-off SolenoidA6 Float HydraulicsA7 Rear WiperA8 Front / Rear HornA9 Beacon, Interior LightA10 Hazard IndicatorsB1 Dip BeamB2 L.H. Side LightsB3 R.H. Side LightsB4 Front Work LightsB5 Rear Work LightsB6 Junction BoxB7 Heater MotorB8 Front Wash/wipeB9 Reverse Alarm, Brake LightsB10 Direction Indicators

Fuse Colour CodeOrange - 5 amp Red - 10 amp Blue - 15 amp

Light Bulbs

Work lights 55 W Interior lights 10 WBeacon 70 W Indicator lights 21 WWarning lights 1.2 W Side lights 5 W

Relays

The relays are located behind panel H.

Up to m/c no. 752370 From m/c no. 752371(Figure Y) (Figure Z)1 Work Light 1 Neutral Start2 Park Brake 2 Isolator3 Ignition 3 Ignition4 Isolator 4 Park Brake5 Horn 5 Alarm Buzzer6 Neutral Start 6 Indicator Flasher7 Indicator Flasher8 Alarm Buzzer

4230-3

SS203811

H

1 2 3 4

5 6 7 8

SS262020

Y

1 2 3 4 5 6

SS262021

Z

1 2 3 4 5 6 7 8 9 10

A

B 10 10 10 10 10 10 10

10 10

15

15 15

5 5

5 5 5 5 5 5

SS262020

X






95 95MAINTENANCE

TYRES AND WHEELS

Inflating the Tyres

! WARNINGOver-inflated or overheated tyres can explode. Do notcut or weld the rims. Get a tyre/wheel specialist to doany repair work.5-3-2-4

These instructions are for adding air to a tyre which isalready inflated. If the tyre has lost all its air pressure, callin a qualified tyre mechanic. The tyre mechanic should usea tyre inflation cage and the correct equipment to do thejob.

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctlyfitted on the machine or installed in a tyre inflationcage.

2 Prepare the Equipment

Use only an air supply system which includes apressure regulator. Set the regulator no higher than1.38 bar (20 lbf/in2) above the recommended tyrepressure. (See Tyre Pressures in SPECIFICATIONsection for recommended tyres and pressures for yourmachine).

Use an air hose fitted with a self-locking air chuck andremote shut-off valve.

3 Add the Air

Make sure that the air hose is correctly connected tothe 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 notover-inflate.

Renewing Segments of Optional Non-Inflatable Tyres

Non-inflatable tyres are available as an option. These tyresconsist of a number of individual segments bolted to thewheel rim.

Damaged segments can be renewed individually. Loosenand remove the four nuts and washers A (two each side ofthe wheel). Lift the segment clear by extracting its fixingstuds from the holes in the wheel rim.

Fit a new segment in reverse order to removal, then tightenthe retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).

Checking the Wheel Bolt Torques

On new machines, and whenever a wheel has beenremoved, check the wheel bolt torques every two hoursuntil they stay correct.

Every day, before starting work, check that the wheel boltsare tight.

The correct torques are shown in the table below.

Front Rear

Nm lbf ft kgf m Nm lbf ft kgf m405 298 41 405 298 41

! WARNINGIf, for whatever reason, a wheel bolt is renewed, all thebolts for that wheel must be changed as a set, sincethe remaining bolts may have been damaged.3-3-2-1

4230-2

174460

A






96 96MAINTENANCE

WINDSCREEN WASHER (OPTIONAL)

Fill the windscreen washer bottle D with a suitable liquid.The liquid should contain a de-icing fluid to prevent itfreezing. Do not use engine coolant antifreeze.

4230-3

S263120

D






97 97MAINTENANCE

FLUIDS, CAPACITIES AND LUBRICANTS

4230-4

We recommend you fit only JCB Genuine Parts.

Your distributor will need to know the exact model, buildand serial number of your machine. The machine's serialnumber is stamped on a data plate on the left hand side ofthe cab front wall. (See Identifying Your Machine inINTRODUCTION section.)

The data plate also shows the serial numbers of theengine, the hydraulic pump and the hydraulic motors.Remember that if any of these units have been changed,the serial number on the data plate may be wrong. Checkon the unit itself.

OBTAINING REPLACEMENT PARTS

! WARNINGSome parts of your machine have Warning Decalsattached. Before you fit a replacement part, make sureit has its warning decal, fixed in its correct position.(See Safety Decals in INTRODUCTION section). Contactyour distributor if the decal is missing.2-3-5-2/1

ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION

Engine OilTo machine no. 807552: 8.2 litres JCB High Performance 15W/40 ACEA E2:B2:A2, API CF4/SGFrom machine no. 807553: 10.5 litres

Hydraulic System 45 litres JCB High Performance 10W/30 ACEA E2:B2:A2, API CF4/SGJCB High Performance 15W/40 ACEA E2:B2:A2, API CF4/SG(top up only)

Cooling System 5.5 litres Antifreeze JCB Four Seasons Antifreeze ASTM D3306, BS658011 litres total coolant & Summer Coolant/watermixture (see Coolant Mixtures)

Fuel System 45 litres Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D

Grease Points JCB Special MPL-EP Grease Lithium based NLGI No. 2 consistency including extreme pressure additives

Chain Case Fill to level plug Engine Oil

Slew OilTo machine no. 807225: Fill to level mark JCB HD90 Gear Oil API GL 5From machine no. 807226: Fill to level plug JCB High Performance 10W/30 ACEA E2:B2:A2, API CF4/SG






98 98MAINTENANCE

STORAGE

Storing the Machine

If the machine is not going to be used for an extendedperiod of time, you must store it correctly to preventdeterioration.

1 Thoroughly clean the machine to remove corrosiveproducts.

2 Fill the fuel tank to prevent condensation forming inthe tank.

3 Park the machine on firm level ground (preferablyunder cover). Make sure you do not park the machinein an awkward position that would prevent it frombeing towed at the end of the storage period (in casethe machine will not start).

4 Remove any attachments. Fully crowd the carriageand lower the arm to the ground.

5 Stop the engine.

6 Apply a light coating of suitable grease or petroleumjelly to all exposed ram piston rods.

7 Check all oil levels and replenish if necessary.

8 Check coolant level and condition. Replenish ifnecessary.

9 Remove and charge the battery. Store the battery in awarm dry place and recharge periodically.

10 Check the tyre pressures. Adjust if necessary.

11 Check the machine for worn or damaged parts.Replace if necessary.

12 If possible, raise and securely support the machineon blocks to prevent distortion of the tyres. Otherwiseperiodically rotate the road wheels.

4230-1






111 111OPTIONAL ATTACHMENTS

INTRODUCTION

A wide range of optional attachments is available toincrease the versatil ity of your machine. Only JCBapproved attachments are recommended for use with yourmachine. Consult your JCB Distributor for the full list ofapproved attachments available.

JCB attachments are designed and manufacturedspecifically to suit the machine's hydraulic system,mounting arrangements and safe load requirements.Attachments which are not designed for use with thismachine may cause damage and create safety hazards forwhich JCB cannot be held responsible. In addition themachine's warranty, "CE" and any other legislativecompliance may be affected by the use of non JCBapproved attachments.2-4-1-13/2

Note: The JCB 1CX can accept 803 series and Kubotabuckets. However, because of the different geometry ofthese buckets, the auxiliary pipework must be removedfrom the boom before fitting, or damage to the pipeworkmay result.

! CAUTIONAll hydraulically operated JCB attachments have built-in relief valve protection. This may not be the case withnon-JCB attachments. Before installing a non-JCBattachment on this machine ensure that it is equippedwith relief valve protection. If in doubt, contact yourJCB distributor.3-4-1-2

Note: Auxiliary relief valves can be fitted to the machine'sloader valve block and set to the required pressure.Contact your JCB distributor for more information.

When fitting hydraulically driven attachments which havebeen used on another machine, note that the hydraulicfluids may not be of the same type. Residual fluid in theattachment may not mix with the fluid in the machine anddamage may be caused.

Each attachment is supplied complete with instructions onSafety, Install ing and Removing, Operation andMaintenance. Read and fully understand the informationbefore fitting, using and servicing the attachment. If there isanything you do not understand, ask your JCB distributor.

This section contains safety and cleanliness informationabout Connecting/Disconnecting Hydraulic Hoses. Thisinformation applies to all attachments which require ahydraulic operating supply.

If your machine hydraulic system needs adapting to allowthe correct use of any auxiliary attachment, you mustconsult your JCB distributor. Only trained hydraulic fittersmust re-route hydraulic hoses.

All optional attachments will have limits on their operation.i.e. lifting capacity, speeds, hydraulic flow rates, etc.Always check in the literature supplied with the attachmentand/or in the SPECIFICATION section of this handbook.Some specification limits may also be displayed on theattachment's Data/Rating Plate.

When fitting hydraulically driven attachments which havebeen used on another machine, note that the hydraulicfluids may not be of the same type. Residual fluid in theattachment may not mix with the fluid in the machine anddamage may be caused.

! CAUTIONSome attachments may contact parts of the machinewhen in the fully folded position. Take extra care toavoid damage to the machine.3-4-1-4

Hand Held Attachments

Your machine may be fitted with auxiliary pipework to allowthe use of hand held attachments.

When using a hand held attachment, set the engine toapproximately half speed. If the charge pressure warninglight illuminates, increase the engine speed slightly until thewarning light goes out.

4230-2






! WARNINGHydraulic fluid at pressure can injure you. Make themachine safe before connecting or disconnectingquick release couplings; stop the engine then turn thestarter switch to IGN and operate the attachmentcontrol a few times to vent residual hydraulic pressurein the attachment hoses.3-4-1-3

Before connecting or removing any hydraulic hose,residual hydraulic pressure trapped in the service hose linemust be vented (see Connecting/DisconnectingHydraulic Hoses).

Connecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped inthe service line hoses.

2 Wipe the two faces of the male and female couplingsand make sure they are clean.

3 Make sure that the locking ball in the female couplingis located in one of its slots.

4 Fit the male coupling into the female coupling. Toensure that the coupling is not accidentally released,rotate the female coupling sleeve one quarter of a turnand make sure that the locking ball does not align withthe slot.

Disconnecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped inthe service line hoses.

2 Align the slot in the female coupling with the lockingball.

3 Pull back the sleeve to release the coupling.


QUICK RELEASE COUPLINGS

Flat face quick release couplings allow the operator toremove and install attachments swiftly and efficiently. The1CX attachment pipework has two male couplings fitted onthe loader arms and two on the backhoe. The attachmenthoses have corresponding female couplings fitted.

The quick release couplings should be trouble free andrelatively easy to connect and disconnect, provided theyare kept clean and used correctly. The recommendationslisted below should always apply when using flat face quickrelease couplings.

Finally, please read the correct fitting and releasingprocedures before installing or removing any optionalattachment fitted with quick release couplings.

Quick Release Couplings - Do's & Don'ts

DO wipe the two faces of the coupling and make sure theyare clean before connecting.

DO make sure the outside sleeve (female coupling) ispulled back when disconnecting.

DO connect and disconnect a new coupling two or threetimes to 'work' the PTFE seals - sometimes a new couplingwill stick if the seals have not been 'worked'.

DO use a spanner on the hexagon flats of the couplingwhen fitting adaptors.

DO use a rubber or hide hammer to disconnect a couplingif it sticks - sticking may occur if there is dirt present in thecoupling.

DON'T attempt to re-connect a damaged half coupling -this will destroy the seals and necessitate replacing bothhalf couplings.

DON'T leave the coupling where it may be run over by amachine or otherwise crushed - this will distort the couplingsleeve and prevent correct connection and disconnection.

DON'T clamp on the smooth diameter of the couplingwhen fitting adaptors - always use the hexagon.

DON'T try to turn the sleeve (female coupling) when thecoupling has been disconnected - the locking ball willwedge underneath the sleeve and destroy the coupling.

DON'T damage the faces of the couplings - this canprevent connection and disconnection, or damage sealsand cause leakage.

DON'T try to dismantle the couplings - they are non-serviceable parts. If a coupling is damaged it should bereplaced with a new one.

4230-1

S169490/1







CONNECTING/DISCONNECTING HYDRAULIC HOSES

Some attachments are hydraulically powered. Thefollowing paragraphs describe how to connect anddisconnect the hydraulic hoses safely.

! WARNINGHydraulic Pressure

Hydraulic fluid at system pressure can injure you.Before disconnecting or connecting hydraulic hoses,stop the engine and operate the controls to releasepressure trapped in the hoses. Make sure the enginecannot be started while the hoses are open.INT-3-1-11/1

Connecting the Hoses

1 Stop the Engine

When the engine has stopped turn the starter key toIGN.

2 Relieve System Pressure

Operate the Auxiliary Attachment Control Switch or theAuxiliary Attachment Detent Switch for a short time torelieve residual pressure in the hydraulic circuit.

Turn the starter key to OFF and remove the key.

This will release any hydraulic pressure trapped in thehoses.

3 Connect the Hoses

See Connecting Quick Release Couplings onprevious page.


4 Check for Leaksa Start the engine.b Operate the Auxiliary Control Switch. This will

build up pressure in the hoses.c Switch off the engine. Remove the starter key.

Check for signs of leakage at the hoseconnections.

Disconnecting the Hoses

1 Carry Out Steps 1 and 2 of Connecting the Hoses.

2 Disconnect the Hoses

See Connecting Quick Release Couplings onprevious page.


3 Check for Leaks

See Step 4 of Connecting the Hoses.

4230-1







SHOVELS

The following are some of the shovels available for theJCB 1CX.

1 General Purpose Shovel 0.29 m3 (10.25 ft3)0.32 m3 (11.30 ft3)

2 Light Duty Shovel 0.40 m3 (14.13 ft3)0.48 m3 (16.95 ft3)0.57 m3 (20.13 ft3)

Note that Light Duty Shovels can only handle material witha bulk density of less than 750 kg/m3 (46.80 lb/ft3).

3 Heavy Duty Shovel 0.29 m3 (10.25 ft3)0.32 m3 (11.30 ft3)

4 6-in-1 Shovel 0.29 m3 (10.25 ft3)0.27 m3 (9.53 ft3)

The 6-in-1 Shovel is covered separately in this section.

General Purpose and Light Duty Shovels

Control and operation are covered in Using theAttachments and Site Safety, Quickhitch Control,Working with the Loader and Travelling Position in theOPERATION section.

Most attachments have an integral framework, such as theone shown below, to make them Quickhitch compatible.Others such as the Earth drill, Hammer and compactorrequire a separate frame, (see Attachment Frame).Consult the relevant attachment literature or your JCBDistributor as to the framework required.

4230-2

Typical Quickhitch Attachment Framework

General Purpose Shovel Light Duty Shovel

A174520

A174540A174530







6-IN-1 SHOVEL

The 6-in-1 shovel allows you to load, dig, grab, grade,doze and spread without changing attachments.

It is similar to a normal shovel except that it has anopening clam which is operated by a hydraulic rammounted on the bucket frame.

Safety

Obey all the safety instructions given in the main part ofthis book, plus those given in this section.

Operation

Practise using the 6-in-1 shovel off the job before workingwith it for the first time.

Preparing for Travel

Close the clam then treat as a standard shovel.

Control

The lift, lower, open and close movements of the 6-in-1shovel are controlled by the loader control lever (seeLoader Controls OPERATION section).

Using the 6-in-1 Shovel

Always operate the controls slowly and carefully. Driveslowly and carefully when the bucket is loaded. Keep theshovel low to the ground when moving, this increases yourvisibility and makes the machine more stable.

Loading and Digging

With the clam closed, the shovel can be used as aconventional shovel as described in Working with theLoader in OPERATION section. For higher dumping,open the clam instead of rolling the shovel.

Grabbing

Open the clam and set the shovel directly above theobject to be grabbed. To grab the object, lower the shoveland close the clam.

Auxiliary Attachments Control Switches

Two switches B situated on the Loader Control Lever areused to actuate the hydraulic function of an attachment.

The switches are used to operate the 6-in-1 clam. Theeffect of switch movement will depend on the way thehydraulics are connected. Before using the attachmentoperate the switches to check the function.

Earlier machines are fitted with a three position rockerswitch situated on the top of the Loader Control Lever.The switch is spring return to the central OFF position.

4230-4

A174550

A174560

S202503B

B






Using the 6-in-1 Shovel (continued)

Grading

To grade, open the clam and drag the shovel backwards.When the shovel is full, roll it back and close the clam.

Dozing

To doze, open the clam and drive the machine forward.

Spreading

Load the shovel with the material to be spread. Set theclam opening to suit the size of material and rate of flow.Drag the shovel backwards, allowing it to discharge aneven layer of material as it goes.

Daily Maintenance

1 Clean with the rest of the machine.

2 Check for damage.

3 Check for signs of hydraulic leaks in hoses, adapters,rams.


4 Grease

Total of 4 grease points. (1 and 2 as illustrated, 3 and4 at opposite end.)


6-IN-1 SHOVEL(continued)

4230-1

A174590

1

2 A174600

A174580

A174570







PALLET FORKS

The pallet fork frame includes a Rating Plate which givesits weight and its Safe Working Load.

The forks should always be used in pairs as supplied. Eachfork is stamped with its Part Number and Safe WorkingLoad.

! CAUTIONThe Safe Working Load stamped on each fork is for thefork itself. It is not for the machine to which the forkmay be fitted. Before lifting any load, check the weightof the load against the Safe Working Load of themachine.2-4-5-3

Safety

Obey all the safety instructions given in the main part ofthis book, plus the ones given in this section.

An optional Load Guard can be purchased, see your JCBDistributor for details.

! WARNINGForklift operation is a specialised area of materialshandling. If forks are fitted to the Quickhitch thenoperator training is recommended and, in someterritories a legal requirement.

Failure to comply may render the operator vulnerableto criminal prosecution.2-4-5-1

! CAUTIONLoads can fall off incorrectly spaced forks. Alwaysspace the forks correctly for the load. Make sure theforks are completely under the load before lifting.5-1-4-2

Fitting/Removing Pallet Forks

See Quickhitch Control (OPERATION section).

Operation

Practise using the forks off the job before working withthem for the first time.

Control

The forks are operated by the loader control lever (seeLoader Controls (OPERATION section).

Operate the control carefully when using the forks.

Road Travel

! WARNINGThe Quickhitch forks must not be fitted for road travel.Failure to comply may render the operator vulnerableto criminal prosecution. If the machine has to travel onpublic roads the forks must be removed.2-4-5-4

Adjust the Fork Spacing

1 Position the forks until they are just clear of theground.

2 Move the spring-loaded locking lever to the verticalposition A and slide the fork along the rail.

3 When the fork is in the required position return thespring-loaded locking lever to the horizontal position B,ensuring that the locking pin is fully engaged in a slotin the rail.

Daily Maintenance

1 Oil the spring loaded locking lever.

2 Grease top rail slots.


4230-1

A174610

A

BB







MANURE/SILAGE FORK WITH TOP GRAB

The Manure/Silage fork is fitted with a top grab asstandard which gives extra security to the pay load whenmoving the machine.

The grab is opened and closed by a hydraulic rammounted on the fork frame.

Safety

Obey all the safety instructions given in the main part ofthis book, plus those given in this section.

Operation

Practise using the Manure/Silage fork "off the job" beforeworking with it for the first time.

Control

The l ift, lower, and ti lt movements of the fork arecontrolled by the loader control lever (see LoaderControls OPERATION section).

Auxiliary Attachments Control Switches

Two switches B situated on the Loader Control Lever areused to actuate the hydraulic function of an attachment.

The switches are used to operate the grab. The effect ofswitch movement will depend on the way the hydraulicsare connected. Before using the attachment operate theswitches to check the function.

Earlier machines are fitted with a three position rockerswitch situated on the top of the Loader Control Lever.The switch is spring return to the central OFF position.

Preparing for Travel

Close the grab; then treat as a standard shovel.

Installing and Removing

Apart from connecting and disconnecting the hydraulichoses, the Manure/Silage fork is installed like a standardbucket. See Quickhitch Control in OPERATION section.Close the grab before removing it.

Using the Manure/Silage Fork

Always operate the controls slowly and carefully. Driveslowly and carefully when the Manure/Silage fork isloaded. Keep the fork low to the ground when moving, thisincreases your visibility and makes the machine morestable.

Open the top grab before loading the fork. Close the topgrab on the load before moving the machine.

To unload the fork, raise it to a suitable height, open thetop grab and tilt down.

4230-4

S202503B

B







MANURE/SILAGE FORK WITH TOP GRAB(continued)

Daily Maintenance


2 Check for damage

Make sure the tines are secure and in good condition.

3 Check for signs of hydraulic leaks


4 Grease

Total of 5 grease points.

4230-1

A174620

234

5

1







ATTACHMENT FRAME

Some attachments utilise an attachment frame for installingon a JCB 1CX.

Use the following procedure for Installing/Removing theattachment frame.

Installing/Removing the AttachmentFrame

1 Stand the attachment frame on level ground as shownat A. Drive the 1CX squarely up to the frame, andstop.

2 Lower the loader arm and tilt forward Quickhitch plateB so that the top of the plate is lower than the lip C ofthe attachment frame.

3 Drive the loader forward until the Quickhitch platetouches the attachment frame, then stop.

4 Slowly tilt the plate backwards until it engages theattachment frame lip. Raise the loader arm until theframe is in contact with the Quickhitch plate, top andbottom.

5 Move the Shovel Control Lever to fully roll back theshovel, to allow the Quickhitch to fully engage. Movethe lever back slightly so that the shovel is not at theend of its travel. This is to allow clearance for theQuickhitch push levers to operate.

6 Dismount from the machine or ask a second person tohelp.

7 Push Quickhitch levers X fully towards the middle ofthe Quickhitch plate to engage locking pins Y andsecure the attachment frame.

8 Removal is the reversal of steps 1 to 7 above.

9 Refer to the Owners Manual of the particularattachment for ful l instructions concerning itsinstallation/removal from the attachment frame.

4230-1

S204170

X

B

Y

Y

S202860

A

C







BACKHOE QUICKHITCH

The Backhoe Quickhitch is fitted to the dipper as shown.The Quickhitch permits rapid removal and installation ofthe bucket (and other attachments). It is mechanicallyoperated and does not require any hydraulic connections.

Read the following pages for instructions on how tocorrectly install and remove the Quickhitch assembly andits attachments.

! CAUTIONWhen the Quickhitch is installed and its attachmentfitted, there is a danger of the attachment hitting theunderside of the boom. Operate the boom and dippercarefully when the Quickhitch and its attachment isfitted.2-4-4-2

IMPORTANTTo eliminate premature wear, failure and breakage, theQuickhitch should only be used in conjunction with arockbreaker for short periods. If the machine is to beused for rock breaking over a long period of time, it ispreferable that the rockbreaker is mounted directlyonto the machine.When using a rockbreaker it must always be curledtowards the machine (as a typical digging operation).Never use the rockbreaker as a lever as this will resultin excessive load on the locking mechanism.

! CAUTIONWhen the Quickhitch is fitted to the machine,allowance must be made for the weight of theQuickhitch on the rated operating load. The mass ofthe Quickhitch is stamped on the data plate.2-4-4-2

Installing the Quickhitch

Note: This operation is easier done by two people - one tooperate the controls and one to line up the pivots.

1 Before fitting the Quickhitch, ensure that the tippinglever locking bolt assembly is installed with the nut atposition L.

2 Set the Quickhitch on firm level ground. Use safe andcorrect lifting equipment to move the Quickhitch.

3 Position the machine so that the dipper arm andQuickhitch are correctly aligned as shown forconnection.

! WARNINGIf two people are doing this job make sure that theperson working the controls is a competent operator. Ifthe wrong control lever is moved, or if the controls aremoved violently, the other person could be killed orinjured.2-2-6-5

4 Operate the controls to line up hole A in the dipper withhole B in the Quickhitch. Insert pivot pin C and securewith fasteners H and D.

5 Operate the controls to line up hole E in the tipping linkwith hole F in the Quickhitch. Insert pivot pin G andsecure with fasteners J and K.

Removing the Quickhitch

Removal of the Quickhitch is a reversal of the installationprocedure. Pay particular attention to safety notices.

Maintenance

Inspect daily for broken or missing parts. Remove anydebris from latch hook locking mechanism. If cleaned byhigh pressure water, always re-grease the latch hook pivotpin. Always grease the latch hook pin every week.

4230-1

884512

L

A

E

H

B

D

G

CF

K

J







BACKHOE QUICKHITCH(continued)

Installing Backhoe QuickhitchAttachments

Various attachments can be used with the Quickhitch.Dedicated attachments have integral pivot pins althoughmost attachments are compatible if the pivot pins are fittedin the normal way as shown. The following procedureshows a bucket being installed/removed.

1 Set the attachment on firm level ground. Use safe andcorrect lifting equipment to move the attachment.

2 Position the machine so that the Quickhitch andattachment are correctly aligned for connection asshown at X.

3 Engage the attachment:

a Use the excavator controls to engage jaw A of theQuickhitch with the pivot pin B of the attachment.

b Use the excavator controls to roll the Quickhitch inthe direction of arrow C until the latch hook D hasfully engaged the pivot pin E on the attachment.Due to the light weight of some attachments it maybe necessary to apply a load on the bucket teethto achieve Quickhitch connection.Alternatively use the tommy bar to lever the latchoff, allowing the attachment pivot pin E to locate injaw D of the Quickhitch.

! CAUTIONMake sure that the latch hook has fully engaged.2-4-4-3

c Fit the latch hook locking pin F and secure withlynch pin G.

! WARNINGAlways fit the Quickhitch latch hook locking pin.Failure to fit the pin will result in possible failure of thelatching mechanism. Such a failure would result in thesudden release of an attachment from the machine,you or others could be killed or seriously injured.3-4-1-9

! CAUTIONWhen the Quickhitch is installed and its attachmentfitted, there is a danger of the attachment hitting theunderside of the boom. Operate the boom and dippercarefully when the Quickhitch and its attachment isfitted.2-4-4-2

4230-1

884518

XG

F

C

AD

E

B








Installing Backhoe QuickhitchAttachments (cont’d)

4 If the attachment is hydraulically operated, connectthe hydraulic hoses as follows:

a Stop the engine.

b Turn starter switch on and operate the auxiliaryattachment control switches H to release anyhydraulic pressure trapped in the system. Turnthe starter switch off.

c Fit the attachment hoses to the machine quickrelease couplings. Refer to Quick ReleaseCouplings at the beginning of the OPTIONALATTACHMENTS section.

5 Start the engine and operate the attachment for a fewminutes to allow pressure to build up.

6 Stop the engine and check for hydraulic leaks.


4230-2

S202503B

H








Removing Backhoe QuickhitchAttachments

1 Park the machine on firm level ground.

2 Position the attachment so that it is approximately150 mm (6 in) above the ground.

3 If the attachment is hydraulically operated, disconnectthe hydraulic hoses as follows:

a Stop the engine.

b Turn starter switch on and operate the auxiliaryattachment control switches A to release anyhydraulic pressure trapped in the system. Turnthe starter switch off.


c Disconnect the hydraulic hoses at the quickrelease couplings.

4 Disengage the Attachment:

! WARNINGThe attachment will roll forward when released. Standclear and to one side when releasing the attachment.2-4-4-1

a Remove lynch pin B and locking pin C.

b Insert the tommy bar D (provided) into the hole Eof the latch hook.

c Apply a downward pressure on the bar to releasethe attachments’ rear pivot pin from the latchhook, as shown at X. Remove the tommy barfrom the Quickhitch.

d Rest the attachment on the ground.

e Slowly roll the Quickhitch back andsimultaneously raise the dipper arm to relaese theattachments’ front pivot pin, as shown at Y.

4230-2

884519

BC

DE

8845110

8845111

X

Y

S202503B

A






131 131SPECIFICATIONS

STATIC DIMENSIONS AND SPECIFICATIONS

4230-4

Dimensions

A Overall length(including standard shovel) 3400 mm (11ft 2in)

B Height to cab roof (standard machines) 2252 mm (7ft 4in)Height to cab roof (low canopy machines) 2092 mm (6ft 10in)

C Width over tyres 1556 mm (5ft 1in)D Width over shovel 1580 mm (5ft 2in)E Ground clearance under stabilisers 258 mm (10in)F Ground clearance at centre 323mm (1ft 0in)G Wheel base 1070 mm (3ft 6in)H Rear overhang 977 mm (3ft 2in)J Height to top of backhoe 2209 mm (7ft 3in)

203860

F

A

G H

J

D

E

B

C







STATIC DIMENSIONS AND SPECIFICATIONS

Weight Total SAE(inc. standard shovel, bucket and driver) 2780 kg (6120 lb)

TyresPneumatic- size 10 x 16.5 7 x 15 29-8 x 15 31 x 13.5 x 15 Grassland- pressure bar (lbf/in2) 3.1(45) 4.1 (60) 4.1 (60) 1.7(25)- manufacturer Goodyear/Dico/Armstrong (tubed and tubeless)

Non-inflatable Airboss(on special rim)

Maximum angle of engine operation up to machine number 807552:Continuous operation - 25 degrees in any direction.Intermittent operation (periods of 10 minutes max.) - 35 degrees in any direction.

Maximum angle of engine operation from machine number 807553:Continuous operation - 35 degrees in any direction.

4230-3







OPTIONAL ATTACHMENTS

4230-6

General Purpose Shovel

Width Capacity No. of Teeth

1430 mm 0.29 m3 Nil(56.30 in) (10.25 ft3)

1580 mm 0.32 m3 Nil(62.20 in) (11.30 ft3)

Light Duty Shovel

Width Capacity No. of Teeth

1430 mm 0.4 m3 Nil(56.30 in) (14.13 ft3)

1580 mm 0.57 m3 Nil(62.20 in) (20.13 ft3)

1730 mm 0.48 m3 Nil(68.11 in) (16.95 ft3)

Note that Light Duty Shovels can only handle materialwith a bulk density of less than 750 kg/m3 (46.80 ft3).

Heavy Duty Shovel

Width Capacity No. of Teeth(optional)

1430 mm 0.29 m3 6(56.30 in) (10.25 ft3)

1580 mm 0.32 m3 6(62.20 in) (11.30 ft3)

6-in-1 Shovel

Width Capacity No. of Teeth(optional)

1430 mm 0.29 m3 6(56.30 in) (10.25 ft3)

1580 mm 0.27 m3 6(62.20 in) (9.53 ft3)







NOISE AND VIBRATION DATA

4230-2

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 detailedbelow, with values weighted in accordance with ISO 2631.

Item 4 above measured at the steering control device when machine is travelling over an irregular "Quarry floor" surface, withvalues weighted in accordance with ISO 2631.

The Vibration values are determined from measurements in three perpendicular planes.

Values determined with standard shovel and excavator bucket fitted.

Typical Duties for 1CX machine: Roading (Tarmac)Roading (Rough Terrain)ExcavatingRehandling cycles (including roading type duties)

The tipping loads are for the 1CX machine fitted with a JCB approved fork carrier and forks.

The noise data below only applies to CE marked machines

NOISE CANOPY CANOPY CAB(with front screen) (without front screen)

Standard High-flow Standard High-flow Standard High-flow

1 Noise Level at Operator's Ear (LpA) 85 87 89 87 85 86

2 External Noise Level -Guaranteed Sound Power Level (LwA) 102 103 102 103 102 103

VIBRATION PNEUMATIC TYRES AIRBOSS TYRES

3 Weighted rms acceleration : Whole Body (m/s2) 0.925 1.21

4 Weighted rms acceleration : Hand/Arm (m/s2) < 2.5 < 2.5

TIPPING LOADS

TIPPING OPERATINGLOAD CAPACITY

JCB 1CX 1220 kg (2690 lb) 610 kg (1345 lb)






Distributor PreparationDespatch Sheet

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

First 50 Hours Only

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

Hour reading ................

250 Hours/3 Months

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

Hour reading ................

500 Hrs./6 Months

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

Hour reading ................

1st 6 Monthly LiftingPoint InspectionF2531 (F97) (UK Only)

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

Hour reading ................1000 Hrs./12 MonthsAnnual Ins. & 2nd 6 monthlyLifting Point Insp. (UK only)

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

Hour reading ................

1st 14 Monthly Insp.F2530 (F91) (UK Only)

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

Hour reading ................

1500 Hrs./18 Months

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

Hour reading ................

3rd 6 Monthly LiftingPoint Insp. (18 months)F2531 (F97) (UK Only)

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

Hour reading ................2000 Hrs./24 MonthsAnnual Ins. & 4th 6 monthlyLifting Point Insp. (UK only)

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

Hour reading ................

2nd 14 MonthlyInspection (28 months)F2530 (F91) (UK Only)

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

Hour reading ................

2500 Hrs./30 Months

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

Hour reading ................

5th 6 Monthly LiftingPoint Insp. (30 months)F2531 (F97) (UK Only)

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

Hour reading ................3000 Hrs./36 MonthsAnnual Ins. & 6th 6 monthlyLifting Point Insp. (UK only)

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

Hour reading ................

3500 Hrs./42 Months

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

Hour reading ................

3rd 14 MonthlyInspection (42 months)F2530 (F91) (UK Only)

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

Hour reading ................7th 6 Monthly LiftingPoint Insp. (42 months)F2531 (F97) (UK Only)

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

Hour reading ................

4000 Hrs./48 MonthsAnnual Ins. & 8th 6 monthlyLifting Point Insp. (UK only)

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

Hour reading ................1st 4 Yearly Test &ExaminationF2531 (F96) (UK Only)

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

Hour reading ................

4500 Hrs./54 Months

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

Hour reading ................

9th 6 Monthly LiftingPoint Insp. (54 months)F2531 (F97) (UK Only)

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

Hour reading ................

4th 14 MonthlyInspection (56 months)F2530 (F91) (UK Only)

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

Hour reading ................

SERVICE RECORD SHEET

4230-1






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AL

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Tel

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25 4

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Fax

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1769

8

✁

Issu

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Feb

ruar

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nglis

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SL

P






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JCB 1CX Operators Manual

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Transcript of JCB 1CX Operators Manual