JCB Produces 200,000th Loadall Telescopic Handler | Construction News


JCB has produced its 200,000th Loadall telehandler. The award-winning brand has provided material-handling and lifting solutions for construction, agriculture, and industry for almost four decades.

Launched in 1977 as the JCB 520, the first Loadall was a two-wheel-drive machine with 21-ft lifting height and 2.48-ton maximum lifting capacity.

Previously, contractors had lifted materials with rough-terrain fork lifts, backhoe loaders, and wheel loaders. Over the past 40 years, the JCB Loadall range has expanded to incorporate machines with working heights of up to 65.6 ft. and maximum lifting capacities exceeding 6.61 tons.

With every update, JCB has moved the telescopic handler market forward, introducing four-wheel drive, placing the engine to the side of the chassis to allow a lower boom-mounting position, and offering multi-mode steering with equal-sized wheels to improve maneuverability.

“From very small beginnings, the JCB Loadall has become a very important machine for JCB and for the construction and agricultural industries,” said Lord Anthony Bamford, JCB chairman. “’Revolutionary’ is often a word that is overused, but in the case of the Loadall, it is a perfect description. The way loads are handled on building sites and farms has never been the same since we introduced the Loadall in 1977.”

From that early two-wheel-drive 520 model, the range grew rapidly with the addition of the heavier-lifting 525 in 1980 and the lighter second-generation 520-2 and 520-4 in 1981. The 520-4 introduced four-wheel drive and larger rear wheels for improved traction on construction sites. These models were also notable for the introduction of JCB’s Q-fit implement carriage, which allowed operators to work with a range of buckets and attachments, including pallet forks.

Though the machines were commonly called Loadalls worldwide, it wasn’t until 1982 that JCB officially adopted the name. At that time, JCB introduced its own slick-shifting Synchro-Shuttle transmissions. Servo control levers were added in 1986 for easier operation, particularly in repetitive handling and loading operations.

JCB completely overhauled the Loadall concept in 1989 with rear-engine models that incorporated multi-mode steering and equal-sized wheels all round for improved travel comfort and maneuverability. In addition to front-end, two-wheel steering that made it easier to drive a Loadall down the road, drivers could enjoy turning in tight circles with all-wheel steering or even shuffling sideways in crab-steer mode to get out of an awkward corner or take the bucket edge along the side of a roadway.

However, by 1997, JCB discovered that moving the engine to a side-mounted position between the wheels could lead to further improvements. This allowed a greater reduction in the height of the boom pivot for even better visibility over the right-hand side and to the rear three-quarters while providing unmatched service access to the power unit and cooling pack.

Power and fuel efficiency benefited again in 2005 when JCB introduced its own engine, the 4.4-liter Dieselmax. In 2006, output was increased further for the engine’s debut in the side-engine Loadall. Two versions of this potent engine powered a purpose-built streamliner to a new diesel land-speed record on Utah’s Bonneville Salt Flats.

In response to customer demand for increased performance and lower ownership costs, top-end Loadall models featured a high-capacity, variable-flow hydraulics system with oil pumped only as needed up to 37 gpm (140 lpm).

That same year, the Loadall reached a significant production milestone when it became the first telehandler brand to hit the 100,000 mark. A $9-million investment in manufacturing resources and a second assembly line at the Rocester, UK headquarters factory brought improved production efficiency and flexibility and substantially increased capacity. Just one year later in 2007, JCB would win the Queen’s Award for its ground-breaking 536-70, 535-140 HiViz and 535-125 HiViz models.

These models would be closely followed in 2008 by a completely new side-engine, high-boom design for the North American market. In 2009, JCB built on existing experience with hydrostatic drives in mid-engine compact handlers to develop the 527-58. As the first compact side-engine Loadall with hydraulic propulsion, this enhanced machine offered a great combination of size, maneuverability, driving ease and loading/handling performance.

To meet new emissions standards and performance demands, JCB developed the 4.4-liter EcoMAX engines further, using only cooled exhaust gas recirculation (EGR) and a variable geometry turbo to meet Tier 4 Interim emissions standards.

Installed in high-specification versions of mainstream Loadall handlers in 2012, the EcoMAX also featured a more powerful engine control unit that sharpened its responses and helped deliver more torque and better fuel consumption. JCB also introduced a 74hp (55kW) EcoMAX engine to meet demand for lower operating costs, CO2 emissions and improved efficiency. This served as a popular choice for customers thanks to the exceptionally strong low-speed torque characteristics normally only seen on higher-powered engines.

Also in 2012, JCB launched the heavyweight 550-80*, a 26.25-ft lift machine with a 5.5-ton capacity, designed primarily for arduous loading operations with high-capacity buckets in both waste handling and agricultural markets. This would be closely followed in 2014 by the 560-80*, taking that maximum lift capacity to 6.61 tons. JCB’s highest lifting machine, the five-stage boom 540-200*, also joined the line-up at that time, providing customers with a stable 65.62-ft (20m) lift height.

Today, the Loadall engine features a compact exhaust silencer and selective catalytic reduction (SCR) system housed beneath the hood to meet Tier 4 Final emissions standards without the added hardware and servicing costs associated with the diesel particulate filter (DPF) needed on several competitive machines. The 74hp (55kW) EcoMAX solution really comes into its own as it meets emissions legislation without any requirement for after-treatment, mitigating the need for DEF (AdBlue).  

Hydraulic performance came under the spotlight in 2014 with the introduction of Smart Hydraulics across the 550, 560* and Wastemaster* range, which includes a unique lift cylinder circuit that permits the boom to lower faster under complete control at low engine revs. This regenerative hydraulics system also added cylinder end-stroke damping, a “bucket shake” feature, automated boom suspension and auxiliary venting. Loading cycles were also 20 percent faster, and the system delivered a 15 percent reduction in fuel consumption.

Further evidence of JCB’s unrivalled experience developing both hydrostatic and powershift transmissions emerged with the 2015 introduction of the ultra-compact Loadall 525-60 HiViz with a hydrostatic transmission, full-sized spacious cab and exceptionally low boom mounting design to maximize visibility. The compact machine is just 6 ft (1.8m) high and 6 ft (1.8m) wide.

Since its introduction in 1977, it took almost 30 years for JCB to sell the first 100,000 Loadalls, but it has taken less than 10 years to sell the subsequent 100,000 – a testament to the growing importance of the product and JCB’s strength and dedication in this sector.


1977 JCB launches the 520 two-wheel-drive telescopic handler with 2.48-ton maximum lift and 6.4m-lift height. The heavier lifting 525 was added in 1980.

1981 JCB introduces the lighter second-generation 520-2 and 520-4, introducing four-wheel drive, the Q-fit implement carriage and larger rear wheels for improved traction and flotation.

1982 JCB adopts the “Loadall” name for its telescopic handler range.

1986 JCB Synchro Shuttle transmission provides slicker gear shifts and faster travel speeds.

1987 JCB introduces the light-touch Servo joystick control system.

1989 The new generation JCB Loadall 525-58 and 525-67 feature with mid-engine installation and lower boom pivot improving rearwards visibility. Equal size wheels and multi-mode steering transform maneuverability and traction.

1997 The first side-engine Loadall 530, 540, 532 and 537 models provide first-rate powertrain access and further improved right-hand and rear three-quarters visibility.

2001 JCB introduces its biggest Loadall to date, the 540-170*, offering a 54.8-ft (16.7m) lift height from a four-stage boom.

2005 First JCB engine – the 4.4-liter, 100hp mechanical fuel injection Dieselmax – is installed in rear-engine Loadalls.

2006 JCB Dieselmax engines set a new land-speed record for a diesel-powered vehicle, and the Loadall becomes first telescopic handler brand to reach the 100,000 units production milestone.

2008 JCB Loadall becomes the undisputed “world’s number one telescopic handler.”

2009 Launch of the first compact hydrostatic drive side-engine Loadall, the 527-58 with 2.98-ton lift capacity and nearly 19.69-ft (6m) lift height in a compact and highly maneuverable package.

2012 New 4.4-liter JCB EcoMAX engine with variable geometry turbo brings a 74-hp (55kW) option to the Loadall range.

2013 JCB’s highest-lift Loadall, the 540-200*, launches with a 65.6-ft (20m) five-stage boom. Ultra-compact hydrostatic drive Loadall 525-60 HiViz launches.

2014 Smart Technology package on Wastemaster machines includes regenerative lift cylinder hydraulics speeding up loading cycles by up to 20 percent or cutting fuel consumption by 15 percent.

2015 The Loadall range features JCB EcoMAX T4F engines with simple no-DPF, one-can exhaust SCR emissions solution for Tier 4 Final regulations.

2016 Loadall production hits 200,000 units.

*Models not available in North America

Caption: Loadall MD Ian Pratt (extreme left) and Loadall Operations Director Paul Grys (extreme right)  join employees (l-r) Ian Vickery, Cliff Ferrie, Mick Smith, Dave Bailey, Nick Miller, Paul Stockley and Richard Jenkinson in celebrating the 200,000th Loadall milestone.