Partie 1

General Information 1
Care & Safety 2

Routine Maintenance 3
Optional Equipment A
Body & Framework B
Service Electrics C
Manual Controls D
8027Z
8032Z
Hydraulics E
Transmission F
Track & Running Gear J
Engine K
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: © WORLD PARTS CENTRE,
WATERLOO PARK, UTTOXETER,ST14 5PA,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/9300 Issue 1

Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures and general techniques
associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore, these basic subjects generally
are omitted from this manual, the intention being to convey only more specialised information concerning particular aspects
of a machine or component.
For example, renewal of oil seals, gaskets etc., and any component showing obvious signs of wear oar damage is expected
as a matter of course and, therefore, information of this nature is included only in the context of specialised procedures or
where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned and lubricated where
appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and
ingress of dirt. Finally, please remember above all SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Optional Equipment
B = Body & Framework ...etc
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for
rapid reference.
Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally can
be reversed for assembly.
Torque settings are given as a ‘mean’ figure which may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine.
References to alternative servicing intervals are to be treated on a ‘whichever occurs first’ basis.
9803/9300 Issue 1
Section 1 General Information Section 1
i i
Contents Page No.

Identifying your Machine 1-1
Preparation for Storage 1-2
Preparation after Storage 1-2
* Operation
Introduction 2-1
Before Entering the Cab 2-2
Machine Walk Round Inspection 2-2
Entering/Exiting the Cab 2-3
Cab 2-4
Opening and Closing the Door 2-4
Opening the Windscreen 2-5
Opening the Side Window 2-5
Heater Controls 2-6
Seat Control 2-7
Seat Belt 2-7
Engine and Track Controls, Switches and Instruments 3-1
Track Controls 3-2
Engine Controls 3-3
Switches 3-3
Instrument Cluster 3-5
Digital LCD Fuel Gauge 3-5
Dozer Controls 4-1
Excavator Controls 4-2
Slew Controls 4-3
Swing Boom 4-4
Raise / Lower Boom 4-4
Dipper 4-5
Bucket 4-5
Refuelling the Machine 5-1
Before Starting the Engine 5-2
Starting the Engine 5-3
Jump Starting the Engine 5-4
Cold Climate Warm Up 5-5
Operating in High Temperatures 5-6
Operating in Low Temperatures 5-6
Stopping and Parking the Machine 6-1
Preparing for Site Travel 6-2
Getting the Machine Moving 6-2
Working with the Dozer 7-1
Working with the Excavator 7-2
Installing a Bucket - non Quickhitch Models 7-2
Replacing Bucket Teeth 7-2
Bucket Selection 7-3
Removing a Bucket - non Quickhitch Models 7-3
Installing a Bucket on a Quickhitch 7-4
Removing a Bucket from a Quickhitch 7-5
Working on Slopes 7-5
Digging 7-6
Moving the Machine while Digging on the Level 7-7
Digging Near Walls 7-7
Digging up against Obstructions 7-7
Lifting (Craning) Regulations and Safe Working Loads 8-1
9803/9300 Issue 2*
ii ii
Contents Page No.
Using the Attachments and Site Safety 8-2
Using the Attachments 9-1

Removing a Quickhitch Rockbreaker 9-2
Using Hand Held Tools 9-2
Moving a Disabled Machine 10 - 1

Transporting the Machine 10 - 2
Before Using the Trailer 10 - 3
Securing the Machine 10 - 3
* Service Tools Numerical List 11 - 1
* Sealing and Retaining Compounds 12 - 1
* Service Tools
Section B - Body and Framework 13 - 1
Section C - Electrics 13 - 3
Section E - Hydraulics 14 - 1
Section K - Engine 14 - 2
9803/9300 Issue 2*
1-1 1-1
The machine has a Data Plate attached to the left hand front Explanation of Engine Identification
face of the machine.
Number
The serial numbers of the machine, engine and gearboxes
are stamped on this plate. Code A B C D E
Example KE 50390 J 000001 y
If the engine is replaced, stamp the new serial number in
place of the old one. A Engine Type
B Engine Parts List
Explanation of Vehicle Identification C Country of Manufacture
D Engine Serial Number
Number (VIN) E Year of Manufacture
Code A B C D E
Example SLP 0803 X E 0765001 OSEN ISO9001
J C BAMFORD EXCAVATORS LTD
ROCESTER, STAFFS, ENGLAND
A World Manufacturer Identification SLP = JCB CONSTRUCTOR
B Machine Model 0803 = 803 FM 14063
Product
Identification
C Year of Manufacture VIN Vehicle Identification Number Number
R = 1994 W = 1998 2 = 2002
ENGINE SERIAL NUMBER LH TRACK GEARBOX SERIAL NUMBER
S = 1995 X = 1999 3 = 2003
T = 1996 Y = 2000 4 = 2004 SLEW GEARBOX SERIAL NUMBER RH TRACK GEARBOX SERIAL NUMBER
V = 1997 1 = 2001 5 = 2005
WEIGHT kg ENGINE POWER kW @ RPM
D Manufacturers Location E = England YEAR OF MANUFACTURE
E Machine Serial Number 0765001 H04343
9803/9300 Issue 1
1-2 1-2
Preparation for Storage Preparation after Storage
The operations to place a machine into storage (-15 °C [5 °F] The operations to remove a machine into storage (-15 °C [5
to 44 °C [111 °F]) are given below. °F] to 44 °C [111 °F]) are given below.
1 Park the machine safely with the bucket and dipper 1 Lower the fuel level to ensure that sufficient air space
rams retracted and the dig end outstretched. Lower the exists in the tank.
boom until the bucket rests on the ground.
Lower the dozer to the ground. 2 Check all oil and water levels, adjust contents to correct
levels as necessary.
2 Switch off the engine. Operate controls to release
pressure from the rams. 3 Ensure that the battery is fully charged.
3 Disconnect the battery to prevent discharge. 4 Reconnect the battery.
4 Ensure that the fuel tank is filled to a maximum, leaving 5 Remove the electrical supply from the fuel injection
no air space. pump solenoid.
5 Ensure that the hydraulic tank is filled to maximum on 6 Crank the engine for 20 seconds or until the oil
the sight gauge. pressure warning light goes out.
6 Spray exposed ram rods with Waxoyl. 7 Reconnect the electrical supply to the fuel injection
pump solenoid.
7 Slacken off rubber tracks until no visible spring tension
exists. 8 Start the engine. If the engine fails to start after several
attempts, bleed the fuel system.
9 Adjust track tensions.
10 Grease all lubrication points.
9803/9300 Issue 1
2-1 Operation 2-1
Introduction
This chapter is arranged to guide you step-by-step through
the task of learning how to use the machine. Read it through
from beginning to end. By the end of the chapter you should
have a good understanding of the machine and how to
operate it.
Pay particular attention to all safety messages. They are

there to warn you of possible hazards. Do not just read
them-think about what they mean. Understand the hazards
and how to avoid them.
If there is anything you do not understand, ask your JCB

dealer, he will be pleased to advise you.
When you have learned where the driving controls are and
what they do, practise using them. Practise driving the
machine in a safe, open space clear of other people.
Get to know the "feel" of the machine and its driving

controls.
Move on to the attachment controls only when you can drive

the machine confidently and safely.
Take great care when practising with the attachment

controls. Practise in an open space, keep people clear. Do
not jerk the controls: operate them slowly until you
understand the effect they have on the machine.
Finally, do not rush the job of learning. Take your time and
take it safely.
Remember BE CAREFUL
BE ALERT
BE SAFE
9803/9300 Issue 1
2-2 Operation 2-2
Before Entering the Cab Machine Walk Round Inspection

1 Check for cleanliness:
! WARNING a Clean the windows and light lenses.
Walking or working under raised attachments can be
hazardous. You could be crushed by the attachments or b Remove dirt and debris, especially from around the
get caught in the linkages. linkages, rams, pivot points and radiator.
Lower the attachments to the ground before doing these c Make sure the cab and handrails are clean and dry.
checks. If you are new to his machine, get an experienced
operator to lower them for you. d Clean all safety decals. Replace any that are
missing or cannot be read.
If there is nobody to help you, study this handbook until you
have learned how to lower the attachments. Also make sure 2 Check for damage:
that the slew lock is engaged before doing these checks. a Inspect the machine generally for damaged and
missing parts.
The following checks should be made each time you return
to the machine after leaving it for any period of time. We b Make sure that the bucket teeth are secure and in
advise you also to stop the machine occasionally during good condition
long work sessions and do the checks again.
c Make sure that all the pivot pins are secured
All these checks concern the serviceability of the machine. correctly in place
Some concern your safety. Get your service engineer to
check and correct any defects. d Inspect the windows for cracks and damage
e Check for oil, fuel and coolant leakages beneath the

machine.
! WARNING
You could be killed or injured with damaged tracks. Do
not use the machine with damaged or excessively worn
tracks.
HOP27
3 Check the Tracks (Rubber)

Check for cut rubber and penetration by sharp objects.
Do not use a machine with damaged tracks.
4 Check the engine cover/panels and fuel filler cap

a Make sure the engine cover / panels are fitted and
securely locked.
b Make sure the fuel filler cap is tightly closed (we

also recommend that you lock it).
9803/9300 Issue 1
2-3 Operation 2-3
Entering/Exiting the Cab
! WARNING
Do not enter or exit the cab unless the arm rest or lever
lock is fully engaged (raised position).
To give sufficient clearance to enter or leave the cab, the left

lever lock must be raised.
When the lever lock and control pod are in the raised
position the excavator controls cannot be operated.
Lowering the lever lock to the normal position connects the
excavator controls and allows normal operation.
It is recommended that the engine is switched off before

exiting the machine.
! WARNING
Always face the machine when entering or leaving the
cab. Use the step(s) and handrails. Make sure the
step(s), handrails and your boot soles are clean and dry.
Do not jump from the machine. Do not use the machine
controls or lever locks as handholds, use the handrails.
Failure to follow these instructions could result in
unexpected movement of the machine.
9803/9300 Issue 1
2-4 Operation 2-4
Cab Opening and Closing the Door

The cab is bolted on top of the mainframe and is a welded To open a door from the outside, unlock it with the key
steel construction. The cab has a sliding windows on the provided to release the catch. To open a door from inside,
right side, a hinged door also containing an opening window push lever B. Close the door from the inside by pulling it
and an up and over windscreen. All windows are of firmly using the handle, it will latch itself. The door must be
toughened glass. The cab is fitted with a windscreen in the closed position when operating the machine.
wash/wipe, heater fan, seat and all operating controls and
instruments.
! CAUTION
Do not drive the machine with the door unlatched. It
must be correctly closed when operating the machine.
A386190
9803/9300 Issue 1
2-5 Operation 2-5
Opening the Windscreen Opening the Side Windows and Door

Window
To open the up and over window, hold handles A, press
and hold down securing levers B. Lift the screen into a The side windows are held closed by catches A operated
position parallel with the roof using handles A, secure in from inside the cab.
position by releasing levers B.
To open the windows, operate the catches A and slide the
Note: Care must be taken when lowering the window not to windows to the desired position.
bump the top edge of the lower front window.
To close a window, slide the window fully shut and check
that the catch A has located on the frame.
A A
378000 A386200
9803/9300 Issue 1
2-6 Operation 2-6
Heater Controls
Air can be directed into the cab by selecting the required fan
speed using switch A. Temperature can be selected by
means of rotary dial B.
A B
A395200
9803/9300 Issue 1
2-7 Operation 2-7
Seat Control Seat Belt
! WARNING Fasten the seat belt

Do not adjust the seat with the engine running otherwise
Sit correctly in the seat. Make sure the belt is not twisted.
your legs could knock the control levers.
Push the male fitting A into the buckle B until it latches.
HOP31
Release the seat belt

Depending on the type of machine various adjustments can
be made to the positions of the control levers and the seat
Press button C and pull the recoil side of the belt outwards.
consoles/armrests.
Note: Your machine is fitted with a seat belt, USE IT!
The operators seat can be adjusted for your comfort. A
correctly adjusted seat will reduce operator fatigue. Position
the seat so that you can comfortably reach the controls with
your feet on the cab floor. The seat is adjustable for height
and reach.
! CAUTION
Having adjusted the seat position, ensure the seat
locking lever has engaged fully.
A Backrest angle adjustment

B Horizontal adjustment
C Weight adjustment (50 - 120 kg [110 - 243 lb] )
D Seat cushion tilt control
A
A
B
B
C
C
D
B H26160
C
A386520
9803/9300 Issue 1
3-1 Operation 3-1
Engine and Track Controls, Switches and

Instruments
1 Left Track Control Lever 7 Fuel Gauge
2 Right Track Control Lever 8 Hourmeter
3 Right Hand Controller 9 Ignition Switch
3a Horn Button 10 Accessory Power Socket (Beacon etc.)
4 Dozer Lever 11 Blank
4a Two speed Tracking Switch 12 Windscreen Wash/Wipe Switch
5 Hand Throttle Lever 13 Work Lights Switch
6 Instrument Cluster 14 Rotating Beacon Switch
6a Charge (Fault) Indicator 15 Left Hand Controller
6b Coolant Temperature (High) Indicator 15a Slew / Swing Selector Switch
6c Not operational on this machine
6d Two Speed (High Engaged) indicator
6e SAE Controls (selected) indicator
6f Glow Plugs (On) indicator
6g Air Filter (Blocked) indicator
6h Not operational on this machine
6j Not operational on this machine
6k Engine Oil pressure (Low) indicator
1 2
15a 3a
11 12 13 14
15 3 4a
4
10
6a 6b 7 6c 6d
9
6k 0 1 SAE 6e
6j 6h 8 6g 6f
H52200
9803/9300 Issue 1
3-2 Operation 3-2

Instruments (continued)
Track Controls
The two tracks are controlled by a pair of control levers A in Forward
front of the seat. Each lever controls one track and is spring
loaded to a central position. In this position the track does To move the machine forward, push both levers forward.
not operate. The left side lever controls the left track. The Release the levers to stop.
right side lever controls the right track. The two levers can
be operated individually or together as necessary to move Reverse
the machine as required. This can be done using one hand
or both, or by using the spring-loaded pedals D. An increase To move the machine backward, pull both levers backward.
in speed can be achieved by operating the push button Release the levers to stop.
switch B located in the dozer lever. When high speed is
selected indicator C will illuminate. Turn
To turn the machine whilst travelling, move the lever back

! WARNING towards the central position on the side towards which you
Make sure that all persons are clear before moving. want to go e.g. move the left lever back to turn left. This
causes one of the tracks to move slower than the other. The
faster moving track will push the machine around. Release
! WARNING the lever to stop.
The track controls operate as described when the dozer
is located in front of the windscreen. If the dozer is Spin
positioned behind the cab, the lever operation will be
reversed. It is advisable when tracking to always To spin the machine around though 360º, without moving it,
position the dozer to the front of the machine. operate one lever, in a forward position and the other in a
reverse position. This will cause the tracks to drive in
opposite directions and hence push the machine around.
A A
D D
H52240
9803/9300 Issue 1
3-3 Operation 3-3

Engine Controls
Engine Speed
A hand operated throttle lever in the cab, controls the speed

of the engine.
Move the lever to increase or decrease the engine speed.

The lever can be left in any position between idle and
maximum as required.
Engine Start / Stop
To start and stop the engine use the starter switch, see
Switches on the following page.
H52250
Switches
Starter Switch
This is operated by the starter key. It has four positions. The

key can only be removed when in the 'O' position.
0
I
O Off/Stop Engine
Turn the key to this position to stop the engine. Make
sure the controls are in neutral and the excavator and
dozer are lowered before stopping the engine. II
I On
Turning the key in this position connects the battery to
the electrical circuits The key will spring back to this
position when released from ll.
III
II Heat Position
Holding the key in this position switches on the glow
plugs. The glow plugs warm the engine combustion
chambers for cold weather starting. Do not hold in this
position for more than 15 seconds. The key will spring H04432
back to I when released.
lll Start
Operates the starter motor to turn the engine.
Note: Do not operate the starter for more than 20 seconds

at one time.
9803/9300 Issue 1
3-4 Operation 3-4

Switches - continued
Work Light Switch B Horn Button D (not illustrated)

On/Off Switch This is a push button switch located in the R.H. excavator
control lever.
Windscreen Wash/Wipe Switch C Press the switch to activate the horn.
Press the switch down once to switch the windscreen wiper
On. Cab Light E (not illustrated)
A cab light is situated on the leftt side of the cab, above the
Put the switch to the off position to switch off the door. It is operated by pressing either end of the light lens.
windscreen wiper, which will then self park.
Blank position F
To operate the Wash function, press the switch past the
wipe position. Flashing Beacon Switch G
On/Off Switch
Functions only with the starter switch at I. Functions with ignition On or Off
F C B G
9803/9300 Issue 1
3-5 Operation 3-5

Instrument Cluster
Indicators for the engine and related systems are mounted in
the instrument cluster in the R.H. console.
A Charge (Fault) Indicaton.

Indicates Alternator operation, illuminates RED when a B D
Fault occurs. A H
B Coolant Temperature (High) Indicator.
Illuminates RED when coolant temperature is too high.
C 0 1 SAE E
C Engine Oil (Low) Indicator.
h
Illuminates RED when engine oil pressure is too low.
F
D Two Speed (High Engaged) Indicator. H G
Illuminates GREEN when high speed is engaged. H 379920
E SAE Controls (Selected) Indicator.

Illuminates Green when SAE control pattern is selected.
F Glow Plugs (On) indicator.

Illuminates YELLOW when the Glow Plugs are
energised.
G Air Filter (Blocked) indicator

Illuminates YELLOW when the Air Filter is blocked.
H Indicators not fitted on this machine.
Digital LCD Fuel Gauge

Fuel Tank Level Indication
Full Tank All bars illuminated.

Filler symbol illuminated.
4 bars to Full Filler symbol illuminated.

All bars illuminated and 1 0 1 0 1 2
reducing as level drops ie.
11 bars, 10 bars, 9 bars etc.
h h
4 bar to 3 bar Buzzer gives 3 short beeps.
Pump symbol starts to flash.
3 bar to 1 bar Pump symbol remains flashing

1 bar illuminated (nearly empty)
0 bars illuminated (tank empty).
3 0 1 0 1 4
Note: The flashing of all fuel level bars and the filler pump
symbol, indicates a fault in the fuel sender circuit. Contact h h
your JCB dealer.
379930
Audible Warnings
A buzzer will sound if any of the following display a machine If the fault is ignored the buzzer will sound continuously for
fault. 180 seconds, after which it will sound intermittently, 1
second on, 2 seconds off.
Charge indicator
Coolant indicator Switch the ignition off, to reset all operations.
Engine oil pressure indicator
Air Filter indicator (see instrument cluster illustration)
9803/9300 Issue 1
4-1 Operation 4-1
Dozer Controls
The dozer is operated by a single control lever on the Raise dozer 'A'
right side of the cab. This lever is spring loaded to the To raise the dozer pull the lever backward. At the required
central position. In this position the dozer will not move. position release the lever.
! CAUTION Lower dozer 'B'

To lower the dozer push the lever forward until an increased
Before operating the dozer, make sure that large rocks
resistance is felt and the blade moves. At the required
or other objects are not between it and the tracks that
position release the lever.
can jam the mechanism.
HOP34
! CAUTION
Before stopping the engine lower the dozer blade to the
ground.
HOP35
A
A
B H52260
9803/9300 Issue 1
4-2 Operation 4-2
Excavator Controls
The slew lock is situated in the seat base. Lift and turn it Most excavating movements are achieved using a
through 90º to unlock. Ensure it is UNLOCKED before combination of both controllers at the same time. Practise
operating the excavator controls. such movements until you are familiar with the operations
that can be achieved safely.
The excavator controls consist of those levers which operate
the boom, dipper and bucket and swing the machine. ! WARNING
When using the boom and dipper fully extended, take the
There are two excavator controllers A and B which control
following precautions, otherwise the machine could get
all the functions. The controls are situated in the operators
damaged or become unstable and a danger to you and
seat armrests. Raising the left armrest when leaving the cab
other people.
prevents the services operating. When re-entering the cab,
ensure the armrest is replaced firmly to ensure correct
Make sure you do not exceed the working capacity of
operation.
the boom at maximum reach.
The left side controller A controls excavator swing and cab
Swing the boom slowly to prevent any chance of the
slew, via a selector switch C in the controller, it also controls
machine becoming unstable. For the same reason avoid
dipper functions.
dumping downhill if possible.
HOP36
The right side controller B controls boom and bucket
functions as standard.
! CAUTION
It is possible to specify SAE style operating functions i.e. left Do not excavate on hard or rocky ground with the boom
controller A controlling swing/slew and boom. The right set diagonally across the undercarriage. This induces a
hand controller B controlling dipper and bucket operation. rocking motion that can cause damage to the track
Both controllers are spring loaded to the central position. In gearbox sprockets and tracks.
HOP37
this position related services will not operate.
C
B
A
H52240
9803/9300 Issue 1
4-3 Operation 4-3
Excavator Controls (continued)

Before slewing the mainframe ensure the slew lock D is
disengaged, (the up position).
D
The slew/swing function is selected by operation of a single
switch in the left hand controller.
The control will always default to slew function when the

ignition is switched off.
The machine should be set for slew operation. Ensure you

are in slew mode by operating the left hand control lever and
noting the movement.
Slew mainframe left

To slew the cab to your left, move the left controller to the
left. Release the controller when you have moved to the
desired position.
Slew mainframe right

To slew the cab to your right, move the left controller to the
right. Release the controller when you have moved to the
desired position.
To select swing press button on left hand controller once.
Swing boom left

To swing the boom to your left, move the left controller to
the left. Release the controller when you have reached the
desired position.
Swing boom right

To swing the boom to your right, move the left
controller to the right. Release the controller when you have
reached the desired position.
! CAUTION
When the requirement for boom swing has finished,
position boom to the straight ahead configuration and
reset machine to 360º slew by pressing the button on the
`left hand controller once.
9803/9300 Issue 1
4-4 Operation 4-4

Raise boom
! WARNING To raise the boom pull the respective controller backwards
Thoroughly warm the hydraulic oil before operating the A. Release the controller when the boom has reached the
excavator services. To ensure smooth boom operation desired position. The boom ram incorporates damping at the
damping is incorporated into the boom lift circuit, this limit of boom raise, reducing the speed of the ram,
means when boom raise is released, the boom may eliminating shock loadings.
continue to rise for a fraction of a second if the oil is not
at the correct operating temperature. Before selecting Boom boost
boom up, check there are no overhead obstructions or Partial selection of the controller will limit the speed of boom
electric power cables. raise. Boom Boost is automatically engaged when controller
is fully selected.
Lower boom
! CAUTION To lower the boom, push the respective controller forwards
The boom service is operated by the R.H. controller on B. Release the controller when the boom has reached the
standard ISO control machines or by the L.H. controller desired position.
on the optional SAE control pattern machines.
HOP41
B B
SAE ISO
A
A
379310
9803/9300 Issue 1
4-5 Operation 4-5
! CAUTION
The dipper service is operated by the L.H. controller on
B B
standard ISO control machines or by the R.H. controller
on the optional SAE control pattern machines.
HOP42
ISO SAE
Dipper In
To bring the dipper in, pull the respective controller
backward A. Release the controller when the dipper is at the
A A
desired position.
Dipper Out
To push the dipper out, push the respective controller
forward B. Release the controller when the dipper is at the
desired position.
B
A
379320
Close bucket
To close the bucket (to gather a load), move the right
controller to the left A. Release the controller when the
bucket is closed sufficiently.
Open bucket
To open the bucket (to dump a load), move the right A B
controller to the right B. Release the controller when the
bucket is open far enough.
A
B
379330
9803/9300 Issue 1
5-1 Operation 5-1
Refuelling the Machine
! WARNING
Diesel fuel is flammable. Keep flames away from the
machine. DO NOT smoke while fuelling the machine or
working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not
follow these precautions.
INT-3-2-2
! CAUTION
Spilt fuel may cause skidding and therefore accidents.
Clean any spilt fuel immediately.
Do not use fuel to clean the machine. A
When refuelling, unlock and remove filler cap A, (choose a

well aired and ventilated area), add the amount of fuel
required, replace filler cap and lock the cap in place.
At the end of every working day, fill the tank with the correct
type of fuel. This will prevent overnight condensation from
developing in the fuel. Do not fill the tank completely, leave
some space to allow the fuel to expand
A391090
9803/9300 Issue 1
5-2 Operation 5-2
Before Starting the Engine

Note: Read Operating in Low Temperatures or Operating in
High Temperatures in operation section if you will be using ! WARNING
the machine in very hot or cold climates. Loose articles can fall and strike you or roll on the floor.
You could be knocked unconscious, or the controls
! WARNING could get jammed. If that happens you will lose control
of the machine.
Before lowering the attachments to the ground, make
HOP45
sure that the machine and the area around it are clear of
other people. Anyone on or close to the machine could
e Remove or secure all loose articles in the cab, such
fall and be crushed by the attachments, or get caught in
as lunch boxes, tools etc.
the linkages.
HOP43
f Check round the cab for loose or missing bolts,
screws etc. Fit new ones or tighten where
1 Lower the attachments to the ground.
necessary.
Lower the excavator bucket and dozer to the ground, if
they are not already there. They will lower themselves
g Inspect the seat belt and its mountings for damage
under their own weight when you operate the controls.
and excessive wear.
Operate the controls carefully to control the rate of
descent.
h Check that the following are in working order:
Lights, Horns, all Switches and Wiper.
2 Do a pre-start inspection.
For your own safety (and others) and for a maximum
j Check the excavator lever gaiters are not damaged
service life of your machine, do a pre-start inspection
or loose, replace or secure as required with new
before starting the engine.
fasteners.
a If you haven't already done it, do a walkround
3 Adjust the Seat
inspection of the outside of the machine. See before
Adjust the seat so that you can comfortably reach all
entering the cab in operation section
driving controls. You should be able to operate the
control pedal with your back against the seat back.
b Remove dirt and rubbish from the cab interior,
especially round the pedal and control levers.
Ensure the seat locking lever has engaged fully.
c Remove oil, grease and mud from the pedals and
4 Set the hand Throttle Lever
control levers.
Set the hand throttle lever to idle.
! WARNING
Keep the machine controls clean and dry. Your hands
and feet could slide off slippery controls. If that happens
you will lose control of the machine. HOP44
d Make sure that your hands and shoes are clean and
dry.
9803/9300 Issue 1
5-3 Operation 5-3
1 Start the engine

Move the throttle lever to full speed position. Turn the
starter key to the glow plug position II for approximately
6 seconds to warm the engine combustion chambers.
Note: Outside temperatures below 0° C (32° F) will require

extended times. 0
I
Turn the starter key further to position lll and hold it there
until the engine starts; do not exceed 20 seconds. If the
engine does not start, return to the OFF position before
repeating step 1. II
2 Check the indicators
! CAUTION
Once the engine has started, move the throttle lever to
the idle position. Check that all the warning lights have III
gone out. Do not race the engine until the 'oil pressure
low' light has extinguished.
If any indicator fails to extinguish, or if they illuminate HO4432

while the engine is running, make the machine safe, stop H04432
the engine and investigate the cause. HOP46
3 Warm up the engine and hydraulics

Allow the engine to warm up at idle speed for five
minutes. If the engine has been jump-started, remove
the booster cables (see jump starting the engine).
Operate the excavator a few times to help warm up the
hydraulic system.
9803/9300 Issue 1
5-4 Operation 5-4
Jump Starting the Engine

Note: Read battery pages in section C of this handbook d Connect the other end of this cable to the negative
before carrying out any work with the battery. (-) terminal on the booster supply.
Follow the instructions on this and the following page to 5 Do the pre-start Checks
start the engine using booster cables. Your machine has a See before starting the engine
12 V starting system. The negative (-) terminal on the battery
is connected to frame earth. 6 Start the engine - see Starting the Engine
! WARNING 7 Disconnect the Booster Cables

a Disconnect the cable from the machine frame earth,
If you try to charge a frozen battery, or jump start and
then disconnect if from the booster supply.
run the engine, the battery could explode.
b Disconnect the positive booster cable from the
Do not use a battery if its electrolyte is frozen. To
positive (+) terminal on the battery, then disconnect
prevent the battery electrolyte from freezing, keep the
it from the booster supply.
battery at full charge.
8 Fit battery cover (if required).
! WARNING
Before lowering the attachments to the ground make 9 Refit items removed to gain access to the battery.
sure the machine and the area around it are clear of
people. Anyone on or close to the machine could fall and ! WARNING
be crushed by the attachments, or get caught in the
Keep metal watch straps and any metal fasteners on
linkages.
your clothes, clear of the positive (+) battery terminal.
HOP43
Such items can short between the terminals and nearby
metal work. If this happens you can get burned.
1 Lower the Attachments to the Ground
Lower the excavator bucket and dozer to the ground. If
Make sure that the fuel filler cap is tightly fitted. Make
they are not already there. They will lower themselves
sure that all spilt fuel is cleaned away from the battery
under their own weight when you operate the control.
area.
Operate the control carefully to control the rate of HOP48
descent.
2 Set all switches in the cab to off
! CAUTION
The booster supply should not be higher than 12 V.
Using a welder or higher voltage supply will damage
your machine's electrical system.
! CAUTION
Do not connect two batteries together to give 24 V. This
could burn out the glow plugs and damage the starter
motor.
3 Remove the left hand mainframe skirt to gain

access to the battery.
4 Connect the Booster Cables

a Remove battery cover if fitted.
b Connect the positive booster cable to the positive

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

frame earth on the machine, away from and below
the battery.
Note: A good frame earth is part of the machine frame, free

from paint and dirt. Do not use a pivot pin for an earth.
9803/9300 Issue 1
5-5 Operation 5-5
Cold Climate Warm Up

Before starting work in temperatures below -15 °C (5 °F),
hydraulic fluid must be warmed.
1 Warm up Engine
After starting the engine (see starting engine) set the
throttle lever to mid position and run for 10 minutes.
DO NOT operate any services. After the warm up

period make sure that everyone is clear of the machine.
2 Warm up Hydraulic Oil

a Increase engine speed to maximum. Warm the
hydraulic oil by repeatedly selecting bucket crowd
by moving the right hand lever to the left for 5
seconds. Repeat for several minutes.
b Select dozer up by moving dozer control lever

backwards, keep selected for one minute.
3 Warm up Hydraulic Circuit

a Reduce engine speed by moving throttle lever to
mid position.
b Raise and lower boom from ground level to full

height five times.
c Stroke the dipper fully in both directions, five times.
d Rotate the bucket fully in both directions, five times.
e Swing the upper structure clockwise for one

revolution and stop. Swing the upper structure anti-
clockwise for one revolution and stop.
f Repeat step 3c three times.
4 The machine should now operate correctly. Should

operation still appear slow, then steps 3b and 3c may
be repeated.
9803/9300 Issue 1
5-6 Operation 5-6
Operating in Low Temperatures Operating in High Temperatures

In low temperature situations, take the following In high temperature situations, take the following
precautions. They will make for easier starting and prevent precautions to prevent possible damage to the machine.
possible damage to your machine.
1 Use the correct viscosity engine oil
1 Use the correct viscosity engine lubricating oil. See Fluids, Capacities and Lubricants - Section 3.
See Fluids, Capacities and Lubricants - Section 3.
2 Use the correct coolant mixture
2 Use a low temperature diesel fuel See Coolant Mixtures - Section 3.
If available. See Fuel System - Section 3.
3 Check the coolant system regularly
3 Use the correct coolant mixture Keep the coolant at the correct level. Make sure there
See Coolant Mixtures - Section 3. are no leaks.
4 Keep the battery at full charge 4 Keep the radiator/oil cooler clean.
Regularly remove dirt and debris from between the
5 Fill the fuel tank at the end of each work period radiator /oil cooler and the engine.
6 Protect the machine when not in use 5 Check ventilation grilles

Park the machine inside a building or cover it with a Ensure the ventilation grilles to and from the engine
tarpaulin. compartment are not blocked.
7 Install cold weather starting aids

In very low temperatures, say -18 °C (0 °F)and below,
additional starting aids may be needed. Examples are
fuel, oil and coolant heaters and extra batteries.
Ask your JCB Dealer for advice.
Note: Do not connect two batteries in series to give 24 Volts

for starting. This could burn out the glow plugs and starter
motor.
8 Remove snow from around the engine cover before

starting.
Otherwise snow could get into the air filter.
9803/9300 Issue 1
6-1 Operation 6-1
Stopping and Parking the Machine
Whenever possible, stop the machine on dry and level

ground.
1 Stop the machine

Release the two track levers A then push the hand
throttle lever B to the idle position. AA
2 Lower the Bucket and Dozer to the ground.
C
3 Stop the Engine and reset ignition key to position I.
C
4 Vent the Hydraulic System
Note: Hydraulic pressure is retained in an accumulator

which must be vented when leaving the machine.
Operate the control levers C to vent the hydraulic

system residual pressure.
5 Remove the Starter Key B

Ensure the waterproof cover is closed on canopy
machines.
6 Switch off all unnecessary Switches

If you are leaving the machine, make sure that all
switches are set to off. 379190
! WARNING
Ensure that the excavator is in a safe condition
HOP49
7 Leave and Secure the machine

Raise the left armrest or engage the lever lock(s). Use
the handrail to leave the cab. If you are leaving the
machine for a long period, close and latch the window
and lock the door. Make sure that the fuel filler cap is
locked.
9803/9300 Issue 1
6-2 Operation 6-2
Preparing for Site Travel
! CAUTION
Always drive the machine with the excavator positioned A
at the same end as the dozer, especially on hard and
rocky ground.
Travelling position A
(level site conditions)
(Activate warning beacon if fitted)
Cab facing forward over dozer, excavator as shown, dozer

blade fully up.
Position boom fully up, operate dipper fully in and bucket

fully crowded, i.e. bucket rotated fully towards cab.
B
Travelling position B
(uneven site conditions)
(Activate warning beacon if fitted)
Lower the boom so that the bucket or attachment is

approximately 150 mm (6 in) from the ground.
150mm
(6 in.)
379340
Getting the Machine Moving

After you have warmed up the engine, move off as
described below. Read Operating Hints and Warnings first.
Operating hints
The machine does not have gears. Do not overwork the 1 Check your seat
engine unnecessarily. Operate at an engine speed suitable Make sure that the seat is secure and correctly
for the duty being carried out. adjusted.
Note: Too low an engine speed may result in lack of dipper Fasten the seat belt.
control.
2 Mainframe Slew Lock
When moving the machine, keep it under control at all times. Make sure that the mainframe slew lock is disengaged.
Stay alert for obstructions and possible hazards.
3 Start the Engine
Approach deep mud slowly. See Starting the Engine.
4 Move the machine

! WARNING a Check that the attachments are in the travel
You and others could be killed or injured if you reverse position. Make sure that it is safe to move off.
direction on the move, because the change in direction
will be sudden and without warning to others. b Take hold of both track control levers in one hand.
Always slow down and stop gently before changing from c Move the levers forward or backward as required
forward to reverse or vice versa. and pull the throttle lever slowly backward until the
HOP51
desired speed is attained.
To increase tracking speed operate the two speed

tracking switch. See Engine and Track Controls.
9803/9300 Issue 2
7-1 Operation 7-1
Working with the Dozer
Remember that you will be driving the machine while you are
using the dozer. Keep alert for bystanders, animals and
possible hazards.
Ensure the slew lock is engaged when working with the

dozer.
Dozing and Grading Backfilling
Keep the bottom of the dozer parallel to the ground. When When backfilling on a slope, pile the material on the high
grading a site remove high spots first, then use this soil to fill side of the trench whenever possible.
in troughs. Do not use excessive downward pressure on the
dozer or machine traction could be lost. When working with Set the dozer level with the ground. Work at right angles to
the dozer, set the excavator in line with the machine, as for the trench filling a dozer's width at a time. Leave any spillage
road travel. Keep the dozer high when travelling as this until the trench is filled. Use the spillage to finish the job by
increases the machines ground clearance. driving the length of the trench with the dozer low to the
ground.
Scraping and Cutting
If a deep cut is to be made, do it in steps of about 50 mm (2

in). Do not forget to adjust the dozer height when the
machine’s tracks enter the cut.
379350
9803/9300 Issue 2
7-2 Operation 7-2
Working with the Excavator

Installing a bucket - non Quickhitch models Replacing bucket teeth
(See Bucket Selection)
1 Position the Bucket
Note: This job is easier done by two people - one to operate Make sure that the bucket is resting flat on the ground.
the controls and one to line up the pivots.
2 Switch off the Engine
1 Position the Bucket Remove the starter key.
Set the bucket flat on level ground, using a suitable
lifting device. 3 Remove a Tooth
Remove the nut and bolt C and the tooth D.
! WARNING
4 Install a Tooth
DO NOT use your fingers through the holes to align the
Position the tooth D and fit the bolts C.
links
HOP65
2 Engage the Dipper

If necessary move the machine to align the pivot pin
holes. Carefully align the holes in the dipper and bucket
link with the bucket. Fit the pivot pins B and lynch pin
A.
C
A D
379230
9803/9300 Issue 1
7-3 Operation 7-3
Working with the Excavator (continued)

Bucket Selection
! WARNING
The bucket selected should be the correct width to suit G
the hole/trench to be excavated. However, if the hole F
width demands the larger bucket, consideration should
be given to the density/weight of the material to be
moved affecting the stability of the machine especially if B
working on a slope. If there is danger of the machine's
stability being compromised, then select a smaller A
bucket or reposition the machine. D
Use the 300 mm (12 in) wide bucket for narrow C

excavations or for maximum penetration when digging in
hard, rocky or clay soils. E
Larger buckets are ideally suited to bulk shifting light or

loose materials.
H25960
! WARNING
When buckets 750 mm (30 in) or wider are fitted to the
machine, use extreme caution in operation to avoid
contact with the cab.
Removing a bucket - non Quickhitch models
1 Position the Boom

Swing the boom so that it is straight in front of the
machine. Rest the bucket on level ground, with the
dipper approximately vertical and the bucket flat to the
ground. Block the bucket to prevent its movement.
! WARNING
Stand clear and to one side of the bucket while the pivot
pins are removed: the bucket could roll over.
HOP63
2 Detach the Bucket

Remove the lynch pin A and the pivot pins B.
! WARNING
If two people are doing this job, make sure that the
person working the controls is competent. A person can
be killed or seriously injured if the controls are moved
violently or incorrectly.
3 Withdraw the Dipper

Using the controls, carefully lift the dipper clear of the
bucket.
9803/9300 Issue 1
7-4 Operation 7-4

Installing a bucket on a Quickhitch
(See Bucket Selection)
G
1 Position the Bucket
Set the bucket on firm level ground. Use safe and F
correct lifting equipment to move the bucket .
B
2 Position the Machine
a Position the machine so that the Quickhitch and
bucket are correctly aligned for connection as A D
shown.
b Use the excavator controls to engage jaw A of the C

quickhitch with the pivot pin B of the bucket.
E
c Use the excavator controls to roll the Quickhitch in
the direction of arrow C until the latch hook D has
fully engaged the pivot pin E on the bucket. Due to H25960
the light weight of some buckets it may be
necessary to apply a load on the bucket teeth to
achieve Quickhitch connection.
Alternatively, use the tommy bar to lever the latch

off, allowing the attachment pivot pin E, to locate in
jaw D of the Quickhitch.
! CAUTION
Make sure that the latch hook has fully engaged.
2-4-4-3
d Fit the latch hook locking pin F and secure with

lynch pin G.
! WARNING
Always fit the Quickhitch latch hook locking pin. Failure
to fit the pin will result in possible failure of the latching
mechanism. Such a failure would result in the sudden
release of an attachment from the machine, you or
others could be killed or seriously injured.
! CAUTION
When the Quickhitch is installed and its attachment
fitted, there is a danger of the attachment hitting the
underside of the boom. Operate the boom and dipper
carefully when the Quickhitch and its attachment are
fitted.
2-4-4-2
9803/9300 Issue 1
7-5 Operation 7-5
Removing a bucket from a Quickhitch
Note: Deposit Quickhitch attachments on firm level ground

whenever possible. This will make later refitting easy and
safe. H
1 Park the machine on firm level ground. F
2 Position the bucket so that it is approximately 150 mm

(6 in) above the ground.
J
Z
! WARNING K
The attachment will roll forward when released. Stand
clear and to one side when releasing the attachment.
2-4-4-1
3 Remove lynch pin H, and locking pin F.
4 Insert the tommy bar J into the hole K of the latch hook.
5 Apply a downward pressure on the bar to release the

buckets’ rear pivot pin from the latch hook, as shown at
Z. Remove the tommy bar from the Quickhitch.
6 Rest the bucket on the ground.
7 Slowly roll the Quickhitch back and simultaneously raise

the dipper arm to release the buckets’ front pivot pin, Y
as shown at Y.
Note: Quickhitch procedure applies to most attachments.

H25970
See your attachments instructions for specific procedures.
Working on slopes
! WARNING
25
Failure to observe these precautions may cause the
machine to become unstable and in extreme
circumstances will overturn with potential serious injury
to the operator.
10
! CAUTION
When excavating on level ground, the dozer may be
positioned at either end of the machine to improve
stability. Always lower the dozer blade to the ground.
The machine can operate without detriment to its

systems on inclines of up to 25º. However, on slopes
greater than 10º the operator must use his discretion
and proceed with extreme caution.
When working on inclines, position the dozer for

maximum stability. This may mean the dozer and the
boom are at the same end of the machine, especially if
digging down hill, lower the dozer sufficiently to bring
the machine level. If necessary, to prevent an instability
problem, cut a level platform for the machine to stand
on.
Your machine is fitted with a seat belt, USE IT. A391050
9803/9300 Issue 1
7-6 Operation 7-6

Digging
It is possible when excavating, to use either full machine Start dumping as the bucket approaches the pile. Do not
slew when discharging a loaded bucket, or if conditions waste time by dumping too far from the excavation. Dump
dictate, swinging the excavator end only to the required close to the start dig position. Swing the bucket back to the
dumping area. excavation and start the next dig.
1 To start the dig, reach out with the boom and dipper
and position the bucket as shown. ! CAUTION
Do not use the side of the excavation to stop the bucket.
Slowly close the bucket at the same time bring the
This could damage the machine and cause the sides of
dipper in. Make sure the bucket stays at the same
the trench to collapse.
angle to the ground while it travels. If necessary, at the
same time apply a downward pressure on the boom, to
Backfill the excavation by loading the bucket with soil from
increase the digging force on the bucket.
the pile. Do not push the soil with the side of the bucket.
2 When the bucket is full, close it fully and at the same
Note: Take extra care if extended swing is utilised (see
time move the dipper out a little way. This will keep soil
Excavator Controls - Extended Operation).
from building up under the machine.
3 Slew the machine or swing the bucket to the dump

area.
3 A391060
9803/9300 Issue 1
7-7 Operation 7-7
Moving the machine while digging on the level
When digging a trench or hole which is longer than the

excavator's reach, dig to the required depth and width A
until it is not possible to dig any closer without contacting
the machine.
When this position is reached, move the machine a suitable

distance away from the excavation.
Lower the dozer blade until the machine is level, then

continue digging B.
Tracking on uneven ground
As for the travelling position, except that the bucket C

should be lowered to approximately 150 mm (6 in) above B
ground.
A
C
A391070
Digging near walls
! WARNING
When digging near a wall, take care not to undermine
the foundations. The wall could collapse.
HOP66
Position the machine close to the wall as shown. Use slew

and swing as required to position the bucket for emptying.
Digging up against obstructions
1 Swing left or right as required
2 Position the machine so that the bucket is up against

the obstruction when fully rotated.
A386290
9803/9300 Issue 1
8-1 Operation 8-1
Lifting (Craning) Regulations and Safe

Working Loads
Lifting regulations
The factories Act Construction (Lifting Operations)

Regulations 1961 defines 'Excavators' as 'Lifting
Appliances'. As such the JCB Mini Excavators are subject to
these regulations.
The owner and/or operator must make sure that he fully

understands the laws and regulations concerning the use of
the JCB Excavator. Consult your JCB dealer for further
information.
! WARNING
Do not use the Excavator as a 'Crane'. Consult National
Lifting Regulations.
Safe Working Loads
! WARNING
The safe working load indicated on lifting accessories
such as cranes etc. is not the safe working load of the
machine.
When loads are to be lifted by the excavator, a bucket

must be fitted.
The maximum load which may be lifted depends on the

equipment fitted to the excavator and the laws and
regulations in force at the time and in the country in
which the excavator is being used.
If your machine is equipped to be operated under

'Exemption Certificate' rules, your Exemption Certificate
will specify the Safe Working Loads.
Note: In certain countries Safety Regulations in force call for

the application of specific safety factors. Consult your dealer
for information.
9803/9300 Issue 1
8-2 Operation 8-2
Using the Attachments and Site Safety

This section explains some techniques for efficient and safe ! WARNING
use of the machine and its attachments. Attention is also
drawn to the various safety aspects of operating on site. Overhead electric power cables
Read and understand this section before you start working There is a minimum clearance required for working
with the machine. Practice using the attachments until you beneath overhead power cables. You must obtain details
are completely familiar with the controls and what they do. from you local electric company.
HOP56
Before using the attachments, study the lifting and digging

diagrams in the Specification section of the maintenance
! WARNING
publication. If you will be working with a labourer, make sure that
you both understand what each other will be doing.
Before you start using the machine, tell your workmates Learn and use the recognised signalling procedures. Do
what you will be doing and where you will be working. On a not rely on shouting he will not hear you!
HOP58
busy site, use a signalman.
Remember that your machine is mobile. Whenever possible, ! WARNING

manoeuvre your machine into a position which combines Underground gas pipes
safety with efficiency. If you have to choose remember that Before you start using the machines, find out from your
local gas company if there are any buried gas pipes on
SAFETY MUST COME FIRST! the site.
Some modern gas pipes cannot be detected by metal

Choose the correct attachment for the job. Do not use an
detectors. So it is essential that you get an accurate map
oversize bucket for rocky material. It could overload the
of buried gas pipes before you begin any excavation
system and shorten service life.
work.
! WARNING Hand-dig trial holes to obtain precise pipe locations. If
General site safety you find any cast iron pipes, assume they are gas pipes
Before you start using this machine, inspect the job until you can prove otherwise.
sites. You could be killed or injured if the ground gives
way under your machine or if piled material collapses Older gas pipes can be damaged by heavy vehicles
onto it. Check for potholes and hidden debris, logs, driving over this ground above them. Mechanical digging
ironwork etc. Any of these could cause you to lose must not take place within 500 mm (20 in) of a gas pipe.
control of your machine. Leaking gas is highly explosive.
HOP52
If a gas leak is suspected, contact the local gas
! CAUTION company immediately and warn everyone on the site.
Legal liability Ban smoking, ensure that all naked lights are
You and/or your company could be legally liable for any extinguished and switch off any engines which may be
damage you cause to public utilities. Make sure that you running.
know the locations of all public utility cables or pipes on
the site which could be damaged by your machine. You are strongly advised to make sure that the safety
HOP53 arrangements on site comply with the local laws and
regulations concerning work near buried gas pipes.
! WARNING HOP57
Electrical power cables

You could be electrocuted or badly burned if you get the
machine or its attachments too close to electrical power
cables.
You are strongly advised to make sure that the safety

arrangements on site comply with the local laws and
regulations concerning work near electric power lines.
HOP54
! WARNING
Buried electric power cables
Before you start using the machine, check with your
electricity supplier if there are any buried power cables
on the site.
HOP55
9803/9300 Issue 1
8-3 Operation 8-3
Using the Attachments and Site Safety

(continued)
! CAUTION
Do not travel with the track motors leading particularly
on hard and rocky ground. The recoil units will not
absorb the shocks and damage could result to the track
running gear.
Do not excavate on hard or rocky ground with the boom

positioned diagonally across the undercarriage. This can
produce a rocking motion that could cause damage to
the track gearbox sprockets.
! WARNING
Hill sides
Operating on hillsides can be hazardous, especially
moving across a slope. If the slope is too steep, your
machine could roll over. If you must drive across a slope
keep the attachments close to the ground. Remember
that loose surface material and mud will change the
ground conditions. In any event do not drive across a
slope of greater than 17º.
! WARNING
Reworking old sites
There could be hazardous materials such as asbestos,
poisonous chemicals or other harmful substances buried
on the site. If you uncover any containers or if you see
any signs of toxic waste, stop the machine and inform
the site manager immediately.
! WARNING
Water supplies and drains
Before you start using the machine, check with your
local public water company if there are buried pipes and
drains on the site. If there are, obtain a map of their
locations and follow the advice given by the water
supplier.
You are strongly advised to make sure that the safety

arrangements on site comply with the local laws and
regulations concerning work near buried water pipes
and drains.
HOP62
9803/9300 Issue 1
9-1 Operation 9-1
Using the Attachments

There are two types of hydraulic attachment circuits
available. Single acting or double acting. Both types are
operated by a floor mounted pedal.
Single acting circuit

A
This type powers a dipper mounted breaker A.
Double acting circuit

This type powers reversible attachments such as an auger
B. The double acting circuit can be switched to single acting
operation by means of a valve C located above the valve
block. Rotate the valve fully anti-clockwise for single acting
operation or fully clockwise for double acting operation.
Operate the pedal in the required direction for correct tool D

operation. In non-operating conditions the pedal must be
locked in position D. B
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected C
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1
A395220
9803/9300 Issue 1
9-2 Operation 9-2
Using the Attachments (continued)
Removing a Quickhitch Rockbreaker
Note: Deposit Quickhitch attachments on firm level ground 5 Disconnect the hydraulic hoses.
whenever possible. This will make later refitting easy and
safe. ! WARNING
The attachment will roll forward when released. Stand
1 Park the machine on firm level ground.
clear and to one side when releasing the attachment. 2-
4-4-1
! CAUTION
The rockbreaker must be positioned correctly before 6 Remove lynch pin H, and locking pin F.
attempting to release it from the quickhitch. if incorrectly
positioned, the rockbreaker could swing or fall suddenly 7 Insert the tommy bar J into the hole K of the latch hook.
from the machine when releasing the quickhitch latch
hook. 8 Apply a downward pressure on the bar to release the
rockbreakers’ rear pivot pin from the latch hook,
2 Position the rockbreaker just clear of the ground and at allowing the attachment to swing forward as shown at
an angle such that the rockbreaker does not detach Z. Remove the tommy bar from the Quickhitch.
from the front pivot pin when the Quickhitch is
unlatched. Typically shown at V. 9 Refit the locking pin F and lynch pin H. Failure to refit
the pin will result in the rockbreaker re-latching as it is
! WARNING lowered to the ground. Make sure that the hydraulic
hoses do not become trapped under the attachment.
Hydraulic Fluid
10 Start the engine and carefully lower the attachment to
the ground as shown at Y.
fluid leaks. Do not put your face close to suspected
11 Slowly roll the Quickhitch back and simultaneously raise
the dipper arm to release the rockbreakers’ front pivot
pin, as shown at Y.
INT-3-1-10/1
12 Remember to remove the lynch pin H and locking pin F
before fitting another attachment.
3 Stop the engine.
Installing a Quickhitch Rockbreaker
4 Operate the auxiliary attachment control pedal, this will
release any hydraulic pressure trapped in the system.
Procedure is as installing a bucket.
J
K
V
V
H27200
9803/9300 Issue 1
9-3 Operation 9-3
Using the Attachments (continued)
Using Hand Held Tools
Hand held tools operate from the machine's auxiliary circuit F

via a valve A.
! WARNING
Hydraulic Fluid
fluid leaks. Do not put your face close to suspected
C
INT-3-1-10/1
D
1 Stop the Engine.
2 Operate the auxiliary attachment control pedal, this will

release any hydraulic pressure trapped in the system.
B
3 Attach the valve A to the bucket ram protection plate B.
A
4 Connect the hydraulic hoses C to the auxiliary C
connectors D, making sure they are clean.
5 Connect the hand held attachment to the connectors E, E

making sure they are clean.
6 Lock the auxiliary pedal F in the operating position.

A391080
9803/9300 Issue 1
10 - 1 Operation 10 - 1
Moving A Disabled Machine
! CAUTION
Do not tow a disabled machine. Permanent damage to
the track motors will occur if the machine is towed.
HOP68
If the machine becomes disabled, it must not be towed or

otherwise moved on its tracks. The machine should be
made safe, lifted onto a transporter and moved to a location
where maintenance can be carried out.
Lifting points have been provided on the machine as follows:
1 On each end of the dozer blade at points A.
2 On the boom at point C.
The correct method for 3-point lifting is shown in the

illustration opposite.
When the machine is totally disabled, the boom should be

set to the fully raised position and lifted using the 3-point
lifting method.
H50420
9803/9300 Issue 1
10 - 2 Operation 10 - 2
Transporting the Machine

Preparing for Road Travel
Before loading the machine on to its trailer (see transporting

the machine), remove all loose dirt that may otherwise come
off and obstruct the highway and damage other vehicles.
Note: Before transporting the machine make sure you will

be obeying the local rules and laws regarding machine
transportation of all the areas that the machine will be
carried through.
Make sure that the transporting vehicle is suitable. See

Maintenance section for the dimensions and weight of your
machine. There is a travel height label fitted to the cab.
Try to make sure that the truck driver knows the clearance
height before he drives away.
Note: The transport position height does not include the

truck/trailer height, add the two figures together for the
clearance height.
! CAUTION
Make sure that the two speed tracking selector is set to
low speed before loading or unloading the machine.
9803/9300 Issue 1
10 - 3 Operation 10 - 3
Before Using the Trailer Securing the Machine
! WARNING ! WARNING
Before moving the machine onto the trailer, make sure The machine must be securely tied down to the trailer to
that the trailer and ramp are free from oil, grease and prevent lateral movement, fore-and-aft movement, and
ice. Remove oil, grease and ice from the machine tracks. slewing of the superstructure. Failure to do so could
Make sure the machine will not foul on the ramp angle. cause injury to yourself or others.
HOP69
1 Engage the slew lock. Ensure by operating the slew
1 Remove any dirt or debris from the trailer. control that the slew lock is engaged.
2 Check the operation of the parking brake. 2 Close the bucket. Position the dipper vertically and
lower the boom until the bucket rests on a wooden
3 Check the trailer bodywork for signs of damage. block on the trailer bed.
4 Check that the tyre pressures are correct (consult the 3 Position a wire rope A of suitable breaking strain over
Manufacturer's handbook). the bucket and secure to the trailer shackles.
5 Check that the lights are working and are the correct 4 Place skids B under each track at front and rear to
voltage for the towing vehicle (consult the prevent movement of the machine in the fore-and-aft
Manufacturer's handbook). direction.
6 Check that the breakaway cable is serviceable. 5 Position a wire rope C of suitable breaking strain
around each track frame at front and rear and secure to
! WARNING the trailer shackles to prevent lateral movement of the
machine. (DO NOT tie down over the tracks.)
The safe transit of the load is the responsibility of the
transport contractor and driver. Any machine,
6 Attach wire ropes D of suitable breaking strain over the
attachment or parts that may move during transit must
kingpost and dozer and secure to the trailer shackles to
be adequately secured.
5-2-5-3 prevent the superstructure from swinging.
A D D
B C B
H27220
9803/9300 Issue 1
11 - 1 11 - 1
Service Tools Numerical List 892/00286 Surface Temperature Probe 13 - 3

892/00293 Connector Pipe 14 - 1
Page No. 892/00294 Connector Pipe 14 - 1
331/31069 ARV Test Block 14 - 2 892/00298 Fluke Multimeter 13 - 3
1406/0021 Bonded Washer 14 - 1 892/00706 Test Probe 14 - 2
1604/0006 Adapter 14 - 1 892/00842 Glass Lifter 13 - 1
1604/0008 Adapter 14 - 1 892/00843 Folding Stand 13 - 1
1606/0012 Adapter 14 - 1 892/00844 Long Knife 13 - 2
1606/0015 Adapter 14 - 1 892/00845 Cartridge Gun 13 - 1
1612/0006 Adapter 14 - 1 892/00846 Glass Extractor Handles 13 - 2
4101/0251 JCB Threadlocker and Sealer 12 - 1 892/00847 Nylon Spatula 13 - 3
4101/0451 JCB Threadlocker 12 - 1 892/00848 Wire Starter 13 - 2
4101/0552 JCB Threadlocker and Sealer 892/00849 Braided Cutting Wire 13 - 2
(High Strength) 12 - 1 926/15500 Rubber Spacer Blocks 13 - 3
4101/0651 JCB Retainer (High Strength) 12 - 1 992/12300 Mobile Oven 13 - 1
4102/0551 JCB High Strength Threadlocker 12 - 1 992/12400 Static Oven 13 - 1
4102/0901 JCB Clear Silicone Sealant 12 - 1 992/12600 Static Oven 13 - 1
4102/1212 JCB Multigasket 12 - 1 992/12800 Cut-out Knife 13 - 2
4102/1951 JCB Threadseal 12 - 1 992/12801 'L' Blades 13 - 2
4102/2309 Black Polyurethane Sealant 12 - 1 993/55700 Direct Glazing Kit 12 - 1
4103/2109 Ultra Fast Adhesive 12 - 1 993/69800 Seal Kit 14 - 1
4104/0251 JCB Activator (Aerosol) 12 - 1
4104/0253 JCB Activator (Bottle) 12 - 1
4104/1557 JCB Cleaner/Degreaser 12 - 1 The following parts are replacement items for kits and would
4104/1203 Active Wipe 205 (250 g) 12 - 1 normally be included in the relevant kit numbers.
4104/1206 Active Wipe 205 (30 ml) 12 - 1 Replacement items for kit no. 892/00253
4104/1310 Hand Cleaner 13 - 1 892/00201 Gauge 0 - 20 bar 14 - 1
4201/4906 Black Primer 12 - 1 892/00202 Gauge 0 - 40 bar 14 - 1
816/15118 Test Adapter 14 - 1 892/00203 Gauge 0 - 400 bar 14 - 1
816/20008 Adapter 14 - 1 892/00254 Hose 14 - 1
816/20013 Adapter 14 - 1
816/55038 Adapter/Test Point 14 - 1
892/00041 Deglazing Tool 14 - 2
892/00078 Connector 14 - 1
892/00137 Micro Bore Hose 14 - 2
892/00223 Hand Pump 14 - 2
892/00253 Pressure Test Kit 14 - 1
892/00262 Adapter/Test Point 14 - 1 & 14 - 2
892/00268 Flow Monitoring Unit 14 - 1
892/00269 Sensor Head 14 - 1
892/00270 Load Valve 14 - 1
892/00271 Adapter 14 - 1
892/00272 Adapter 14 - 1
892/00273 Sensor Head 14 - 1
892/00274 Adapter 14 - 2
892/00275 Adapter 14 - 1
892/00276 Adapter 14 - 1
892/00277 Adapter 14 - 1
892/00278 Gauge 0 - 40 bar 14 - 2
892/00279 Gauge 0 - 400 bar 14 - 2
892/00281 Avo Meter 13 - 3
892/00282 Shunt 13 - 3
892/00283 Tool Kit Case 13 - 3
892/00284 Digital Tachometer 13 - 3
892/00285 Oil Temperature Probe 13 - 3
9803/9300 Issue 1
12 - 1 12 - 1
Sealing and Retaining Compounds

JCB Multigasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551
Gasketing for all sizes of flange where the strength of the joint
is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and retaining nuts,
bolts, and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter. 4101/0251
JCB Threadlocker For threads of suction strainer. 4101/0451 50ml
JCB Threadlocker & Sealer A medium to high strength locking fluid. 4101/0552
(High Strength)
JCB Threadseal Medium strength thread sealant (for patch bolts that are re-used). 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of anaerobic 4104/0251 Aerosol
products. 4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives

and sealants. 4104/1557 Aerosol
Direct Glazing Kit For one pane of glass, comprises items marked † below plus
applicator nozzle etc. 993/55700
† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml
† Active Wipe 205 For direct glazing 4104/1203 250 g

4104/1206 30 ml
† Black Primer 206J For direct glazing 4201/4906 30 ml
JCB Clear Silicone Sealant To seal butt jointed glass. Also to seal hub planet gear carrier
when no 'O' ring is fitted 4102/0901
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
13 - 1 13 - 1
Service Tools
Section B - Body and Framework
S186240 S186270
Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the
polyurethane adhesives. application of sealants, polyurethane materials etc.
JCB part number - 4104/1310 (454g; 1lb tub) JCB part number - 892/00845
'
S186250
12V Mobile Oven - 1 cartridge capacity - required to

pre-heat adhesive prior to use. It is fitted with a male S186280
plug (703/23201) which fits into a female socket Folding Stand for Holding Glass - essential for
(715/04300). preparing new glass prior to installation.
JCB part number - 992/12300 JCB part number - 892/00843
S186260
240V Static Oven - available with 2 or 6 cartridge
S186300
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon Glass Lifter - minimum 2 off - essential for glass
request - contact JCB Technical Service installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage during
JCB part number: storage.
992/12400 - 2 cartridge x 240V
992/12600 - 6 cartridge x 240V JCB part number - 892/00842
9803/9300 Issue 1
13 - 2 13 - 2
Service Tools (continued)

Section B - Body and Framework (continued)
S186310 S186340
Wire Starter - used to access braided cutting wire Cut-out Knife - used to remove broken glass.
(below) through original polyurethane seal.
JCB part number - 992/12800
'
S186320 S186350
Glass Extractor (Handles) - used with braided cutting 'L' Blades - 25mm (1in.) cut - replacement blades for
wire (below) to cut out broken glass. cut-out knife (above).
JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
S186330
S186360
Braided Cutting Wire - consumable heavy duty

cut-out wire used with the glass extraction tool Long Knife - used to give extended reach for normally
(above). inaccessible areas.
JCB part number - 892/00849 (approx 25m length) JCB part number - 892/00844
9803/9300 Issue 1
13 - 3 13 - 3

Section B - Body and Framework (continued)
S186470 S186550
Nylon Spatula - general tool used for smoothing Rubber Spacer Blocks - used to provide the correct
sealants - also used to re-install glass in rubber glazing set clearance between glass edge and cab frame.
because metal tools will chip the glass edge.
JCB part number - 892/00847 (unit quantity = 500 off)
Section C - Electrics
Electrical Test Equipment
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Microtach Digital Tachometer
5 892/00282 100 Amp Shunt - open type
6 892/00285 Hydraulic Oil Temperature Probe
7 892/00298 Fluke 85 Multimeter
9803/9300 Issue 1
14 - 1 14 - 1
Service Tools
Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit

892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00254 Replacement Hose
:993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
S188120
Pressure Test Adapters
Pressure Test 'T' Adapters 892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point S200140
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point
S188130
Flow Test Equipment
892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078 Connector 1 in F x 1 in F BSP
1604/0008 Adapter 1 in M x 1 in M BSP
S188150
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
9803/9300 Issue 1
14 - 2 14 - 2
Section E - Hydraulics (continued)
S193850
Hand Pump Equipment
892/00223 Hand Pump

892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in BSP male x 3/8 BSPT male
892/00262 Test Point on 1/4 in BSP male x 1/4 BSP
female adapter
892/00706 Test Probe A408670
892/00278 Gauge 0-40 bar (0-600 lbf/in2)
892/00279 Gauge 0-400 bar (0-6000 lbf/in2) 331/31069 ARV Test Block
Section K - Engine
892/00041 De-glazing Tool for Cylinder Bores (to

assist bedding-in of new piston rings)
9803/8030 Issue 1
Section 2 Care & Safety Section 2
i i
Contents Page No.
Safety Notices 1-1
General Safety 2-1
Operating Safety 3-1
Maintenance Safety 4-1
9803/9300 Issue 1
1-1 1-1
Safety Notices
In this handbook and on the machine there are safety notices. Each
notice starts with a signal word. The signal word meanings are given
below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken it is highly
probable that the operator (or others) could be killed or seriously injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others)
could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could
result in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/9300 Issue 1
2-1 2-1
All construction and agricultural equipment can be Note: This section includes a certain amount of operating
hazardous. When a JCB Mini excavator is correctly operated safety information. But remember that whenever you drive
and properly maintained, it is a safe machine to work with. the machine or operate its controls you are in effect a
But when it is carelessly operated or poorly maintained it machine operator. Therefore you should read and
can become a danger to you (the operator) and others. understand the information given in the Operator Handbook
before driving the machine or operating its controls.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific

warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
General Safety
! WARNING ! WARNING
Clothing Care and Alertness
You can be injured if you do not wear the proper clothing. All the time you are working with or on the machine, take
Loose clothing can get caught in the machinery. Wear care and stay alert. Always be careful. Always be alert for
protective clothing to suit the job. Examples of protective hazards.
clothing are: a hard hat, safety shoes, safety glasses, a well HOP3
fitting overall, ear-protectors and industrial gloves. Keep

cuffs fastened. Do not wear a necktie or scarf. Keep long ! WARNING
hair restrained. Raised Attachments
INT-1-3-6
Raised attachments can fall and injure you. Do not walk or
work under raised attachments unless they are safely
supported.
! WARNING HOP6
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make
sure that lifting equipment is in good condition. Make sure
that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is
strong enough for the job.
! WARNING
Do not use this Excavator as a ‘Crane’. Consult National
Lifting Regulations.
9803/9300 Issue 1
3-1 3-1
Operating Safety
! WARNING ! WARNING
Practice Entering/Leaving
You or others can be killed or seriously injured if you do Always face the machine when entering and leaving the cab.
unfamiliar operations without first practising them. Practise Use the step(s) and handrails. Make sure the step(s),
away from the work site on a clear area. Keep other people handrails and your boot soles are clean and dry. Do not
away. Do not perform new operations until you are sure you jump from the machine, do not use the machine controls as
can do them safely. handholds, use the handrails.
HOP7 HOP12
! WARNING
Machine Condition
! WARNING
A defective machine can injure you or others. Do not operate
a machine which is defective or has missing parts. Make Exhaust Gases
sure that maintenance procedures are completed before Breathing the machine exhaust gases can harm and
using the machine. possibly kill you. Do not operate the machine in enclosed
HOP8 spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
! WARNING drowsy stop the machine at once. Get out of the cab into
Alcohol and Drugs fresh air.
HOP13
It is extremely dangerous to operate machinery when under
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine ! WARNING
or attachments. Be aware of medicines which can cause Visibility
drowsiness. Accidents can be caused by working in poor visibility. Keep
INT-1-3-9
windows clean and use your lights to improve visibility. Do
not operate the machine if you cannot see properly.
! WARNING HOP14
Lifting
Do not lift objects with the excavator or the boom. ! WARNING
HOP24
Regulations
Obey all laws, work site and local regulations which affect
! WARNING you and your machine.
HOP2
Controls
You or others can be killed or seriously injured if you operate
the controls levers from outside the cab. Operate the control ! WARNING
levers only when you are correctly seated inside the cab. Parking
HOP9
An incorrectly parked machine can move without an
operator. Follow the instructions in this Manual to park the
! WARNING machine correctly.
HOP16
Machine Limits
Operating the machine beyond its design limits can damage
the machine, it can also be dangerous. Do not operate the ! WARNING
machine outside its limits. Do not try to upgrade the Work Sites
machine performance with unapproved modifications. Work sites can be hazardous. It is the operator’s
HOP10
responsibility to inspect the site before working on it. Look
for potholes, weak ground, hidden rocks etc. Check for
! WARNING utilities such as electric cables (overhead and underground),
Engine gas and water pipes etc. Mark the positions of the
The engine has rotating parts. Do not open the engine cover underground cables and pipes. Make sure that you have
while the engine is running. Do not use the machine with the enough clearance beneath overhead cables and structure. If
cover open. Engine cover to be kept locked to prevent necessary, contact the local authorities before commencing
unauthorised access. work.
HOP11 HOP15
! WARNING
Safety Barriers
Unguarded machines can be dangerous. In public places, or
where your visibility is reduced, place barriers around the
work area to keep people away.
HOP21
9803/9300 Issue 1
3-2 3-2
Operating Safety (continued)
! WARNING ! WARNING
Communications Safe Working Loads
Bad communications can cause accidents. Keep people Overloading the machine can damage it and make it
around you informed of what you will be doing. If you will be unstable.
HOP23
working with other people, make sure any hand signals that
may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands. ! WARNING
HOP18
Slew Lock
The slew lock must be engaged when transporting the
machine.
! WARNING
Fibre Optic Cables ! CAUTION
If you cut through a fibre optic cable, DO NOT look into the A wide range of optional attachments is available to
end of it, your eyes could be permanently damaged. increase the versatility of your machine. Only JCB approved
attachments are recommended for use with your machine.
Consult your JCB Distributor for the full list of approved
! DANGER attachments available.
Sparks JCB attachments are designed and manufactured
Explosions and fire can be caused by sparks from the specifically to suit the machine’s hydraulic system, mounting
exhaust or the electrical system. Do not use the machine in arrangements and safe load requirements. Attachments
enclosed areas where there is flammable material, vapour or which are not designed for use with this machine may cause
dust. damage and create safety hazards for which JCB cannot be
HOP22
held responsible. In addition the machine’s warranty, ‘CE’
and other legislative compliance may be affected by the use
! WARNING of non-JCB approved attachments.
Earth Drills and Breakers 2-4-1-13/2
Operation of this machine with an earth drill or breaker fitted

will alter machine stability. Refer to the attachments stability ! CAUTION
page before working on inclines. This machine is manufactured in compliance with legislative
HOP26
and other requirements. It should not be altered in any way
which could affect or invalidate any of these requirements.
For advice consult your JCB Distributor.
! WARNING
Passengers Reference should also be made to Optional Attachments
Passengers in or on the machine can cause accidents. The section where appropriate.
INT-1-3-10
JCB Mini-Excavator is a one man machine, do not carry
passengers.
HOP17
! WARNING
Hillsides
Operating the machine on hillsides can be dangerous if
proper precautions are not taken. Ground conditions can be
changed by rain, snow or ice. Check the site carefully, when
applicable, keep excavator end and attachments low to the
ground.
HOP20
! WARNING
Banks and Trenches
Banked material and trenches can collapse. Do not work or
drive too close to banks and trenches where there is danger
of collapse.
HOP19
9803/7130 Issue 1
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Repairs Petrol
Do not try to do repairs or any other maintenance Do not use petrol in this machine. Do not mix petrol with the
work you do not understand. Get a Service Manual diesel fuel; the petrol may rise to the top and form
from your JCB Dealer, or get the work done by the flammable vapours.
JCB Dealer’s specialist engineer.
! WARNING ! WARNING
Modifications and Welding Diesel Fuel
Non approved modifications can cause injury and damage. Diesel fuel is flammable; keep naked flames away from the
Parts of the machine are made from cast iron; welds on cast machine. Do not smoke while refuelling. Do not leave the
iron can weaken the structure and break. Do not weld cast engine running while refuelling.
iron. Contact your JCB Dealer before attempting any
modifications.
! WARNING
! WARNING Rams
The machine’s efficiency will be affected if the rams are not
Metal Splinters kept free of solidified dirt. When parking close all rams as far
You can be injured by flying metal splinters when driving as possible to prevent weather corrosion.
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
! WARNING
! WARNING Hot Coolant
The cooling system is pressurised when the engine is hot.
Electrical Circuits Hot coolant can spray out when you remove the filler cap.
Understand the electrical circuit before connecting or Let the system cool before removing the filler cap. To
disconnecting an electrical component. A wrong connection remove the cap; turn it to the first notch and let the system
can cause injury and/or damage. pressure escape, then remove the cap.
INT-3-2-9/1
! WARNING
Batteries ! WARNING
A frozen battery can explode if it is used or charged. Do not Hydraulic Pressure
use a machine with a frozen battery. Hydraulic fluid at system pressure can injure you. Before
Batteries give off explosive gases. Keep flames or sparks disconnecting or connecting hydraulic hoses, stop the
away. Do not smoke. Make sure there is good ventilation engine and operate the controls to release pressure trapped
when batteries are being recharged. in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/1
! WARNING
Oil ! WARNING
Oil is toxic. If you swallow any oil, do not induce vomiting, 'O' rings, Seals and Gaskets
seek medical advice. Used engine oil contains harmful Badly fitted, damaged or rotted 'O' rings, seals and gaskets
contaminants which can cause skin cancer. Do not handle can cause leakages and possible accidents. Renew
used engine oil more than necessary. Always use barrier whenever disturbed unless otherwise instructed. Do not use
cream or wear gloves to prevent skin contact. Wash skin Trichloroethane or paint thinners near 'O' rings and seals.
contaminated with oil thoroughly in warm soapy water. Do INT-3-2-12
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
! WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
leaks. Do not put your face close to suspected leaks. Hold a
piece of cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid. If hydraulic
fluid penetrates your skin, get medical help immediately.
INT-3-1-10/1
9803/9300 Issue 1

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General Information 1

Care & Safety 2

Publication No. 9803/9300 Issue 1

1 = General Information - includes torque settings and service tools.

Contents Page No.

Contents Page No.

Using the Attachments and Site Safety 8-2

Using the Attachments 9-1

Moving a Disabled Machine 10 - 1

* Service Tools Numerical List 11 - 1

* Sealing and Retaining Compounds 12 - 1

E Machine Serial Number 0765001 H04343

Preparation for Storage Preparation after Storage

3 Disconnect the battery to prevent discharge. 4 Reconnect the battery.

9 Adjust track tensions.

10 Grease all lubrication points.

Pay particular attention to all safety messages. They are

If there is anything you do not understand, ask your JCB

Get to know the "feel" of the machine and its driving

Move on to the attachment controls only when you can drive

Take great care when practising with the attachment

Before Entering the Cab Machine Walk Round Inspection

e Check for oil, fuel and coolant leakages beneath the

3 Check the Tracks (Rubber)

4 Check the engine cover/panels and fuel filler cap

b Make sure the fuel filler cap is tightly closed (we

Entering/Exiting the Cab

To give sufficient clearance to enter or leave the cab, the left

It is recommended that the engine is switched off before

Cab Opening and Closing the Door

Opening the Windscreen Opening the Side Windows and Door

Seat Control Seat Belt

! WARNING Fasten the seat belt

Release the seat belt

A Backrest angle adjustment

Engine and Track Controls, Switches and

Engine and Track Controls, Switches and

To turn the machine whilst travelling, move the lever back

Engine and Track Controls, Switches and

A hand operated throttle lever in the cab, controls the speed

Move the lever to increase or decrease the engine speed.

Engine Start / Stop

This is operated by the starter key. It has four positions. The

Note: Do not operate the starter for more than 20 seconds

Engine and Track Controls, Switches and

Work Light Switch B Horn Button D (not illustrated)

Engine and Track Controls, Switches and

A Charge (Fault) Indicaton.

E SAE Controls (Selected) Indicator.

F Glow Plugs (On) indicator.

G Air Filter (Blocked) indicator

H Indicators not fitted on this machine.

Digital LCD Fuel Gauge

Full Tank All bars illuminated.

4 bars to Full Filler symbol illuminated.

3 bar to 1 bar Pump symbol remains flashing

! CAUTION Lower dozer 'B'

Excavator Controls (continued)

The control will always default to slew function when the