JCB 426, 436, 446 Wheeled Loading Shovel 9803-4160-15 (Preview)
9803-4160
Section1
– General Information
– Introduction
— About this Publication
– Identifying your Machine
— Identification Plates
— Identification Plate
— Explanation of Vehicle Identification Number (VIN)
— Unit Identification
— Typical Engine Identification Number
– Torque Settings
— Zinc Plated Fasteners (golden finish)
— UNF Grade `S’ Bolts
— Metric Grade 8.8 Bolts
— Rivet Nut Bolts/Screws
– Service Tools
— Numerical List Section B – Body and Framework
— Tool Detail Reference Section B – Body and Framework
— Numerical List Section C – Electrics
— Tool Detail Reference Section C – Electrics
— Numerical List Section E – Hydraulics
— Tool Detail Reference Section E- Hydraulics
— Numerical List Section F – Transmission
— Tool Detail Reference Section F – Transmission
— Numerical List Section K – Engine
— Tool Detail Reference Section K – Engine
– Service Consumables
— Sealing and Retaining Compounds
Section2
– Care and Safety
– Safety Notices
— Important Information
— The Operator Manual
— Safety Warnings
— Safety Check List
— Safety – Yours and Others
— General Safety
— Operating Safety
— Maintenance Safety
— Safety Decals
Section3
SectionA
– Attachments
– Optional Attachments
— Quick Release Couplings
— Connecting and Disconnecting
SectionB
– Body and Framework
– Technical Data
— Air Conditioning Option
– Basic Operation
— Air Conditioning
— R134a Refrigerant
— System Operation
— System Control
— Safety Procedures
– Fault Finding
— Air Conditioning
— Visual Inspection
— System Diagnosis
– Service Procedures
— Rivet Nuts
— Fitting Procedure
— Air Conditioning
— Checking Refrigerant Charge Level
— Leak Testing
— Tightening Leaking Hoses
— Refrigerant Charging and Discharging
— Pressure Switch Assembly (Two Switch System)
— Binary Pressure Switch Testing (Single Switch System)
— Condenser
– Air Conditioning
— Early Type
— The Air Conditioning Unit
— The Blower Unit
— Thermostat
— Evaporator
— Pressure Switches
— Later Type
— The Air Conditioning Unit
— The Blower Motor
— Thermostat
— Evaporator
— Air Conditioning – 426 from M532100, 436 from M533700
— 426 from M1231500, 436 from M1305000
— The Air Conditioning Unit
— Filters
— Blower Motor
— Thermostat
— Evaporator
— Expansion Valve
— Heater Radiator
— Binary Pressure Switch
– Cab
— Glazing
— Direct Glazing
— ROP/FOPS Structure
— 426 prior to M1231500, 436 prior to M1305000
— 426 from M1231500, 436 from M1305000
– Bodywork
— Removal and Replacement of the Rear Bodywork
— Removal
— Replacement
– Centre Pivot
— Removal and Replacement
— Removal
— Replacement
– Cooling Pack
— 426 from Serial No. 532500
— Removal and Replacement (426 from Serial No. 532500)
— Dismantling and Assembly
— 436 from Serial No. 534200
— Removal and Replacement
— Dismantling and Assembly
— 426 from M1231500, 436 from M1305000
— Introduction
— Removal
SectionC
– Electrics
– Technical Data
— General Electrical Data
— Light Bulbs
— Fuses and Relays
— 426 to M531064, 436 to M533069
— 426 from M531065, 436 from M533070
— 426 from M531300, 436 from M533300
— 446 from 540000
— 426 from M532100, 436 from M533692
— 426 from M532429, 436 from 534089
— 426 from M532847, 436 from M534468
— 426 from M1231500, 436 from M1305000
— 426 from M1295000, 436 from M1410000
– Service Procedures
— Using a Multimeter
— Measuring DC Voltage
— Measuring Resistance
— Measuring Continuity
— Measuring Frequency
— Testing a Diode or a Diode Wire
— Battery
— Maintenance
—- First Aid – Electrolyte
— Testing
— Specific Gravity Testing
— Alternator
— General Description
— Service Precautions
— Charging Circuit Test
— Alternator Charging Test
— Starter Motor
— Starting Circuit Test
— Electronic Monitoring System (EMS)
— HC11 Display Panel
— C164 Display Panel
— 24 – 12 Volt Power Distribution Board
– Fault Finding
— Introduction to Fault – Finding Techniques
— Harness Routing
— Example of Wire Tracing
— Component Testing
– Schematic Circuits
— 426 to 531064, 436 to 533069
— 426 from 531065, 436 from 533070
— 426 from 531300, 436 from 533300
— 446 from 540000
— 426/436 from March ‘98
— 446 from March ‘98
— 426 from 532100, 436 from 533692
— 426 from 532847, 436 from 534468
— Auxiliary Circuits (426 from 532847, 436 from 534468)
— 436 Machines – Italian Military Only
— 426 from M1231500, 436 from M1305000
— Instrumentation
— ZF Computer and Gearbox Controller
— Front Wipe, Rear Wipe, Heater/AC and Heated Rear Screen
— Front and Rear Worklights and Beacon
— Roadlights
— Radio, Cigar Lighter, CCTV and Tow Hitch
— ESOS, Heated Mirrors, Heated and Suspension Seat, Reverse Fan and Emergency Steer
— 12Volt Trailer Electrics and Loader Functions
— Loader Auxiliaries (Proportional)
— Earthing – Cab and Cab Roof
— Earthing – Front and Rear Chassis
— 426 from M1295000, 436 from M1410000
— Primary Fuses, Ignition Switch and Ignition Relays
— Instrumentation
— ZF Computer and Gearbox Controller
— Tier 3 Engine ECU
— Front Wipe, Rear Wipe, Heater/AC
— Front and Rear Worklights and Beacon
— Roadlights
— Radio, Cigar Lighter, CCTV and Tow Hitch
— ESOS, Heated Mirrors, Heated and Suspension Seat, Reverse Fan and Emergency Steer
— 12Volt Trailer Electrics and Loader Functions
— Loader Auxiliaries (Proportional)
— Earthing
– Harness and Wire Number Identification
— Wire and Harness Number Identification
— Introduction
— Wire Numbers and Functions
— Connector Location and Identification
— 426 from M531064, 436 from M533069
— 426 from M531300, 436 from 533300, 426 from 540000
— Harness Drawings
— Front Chassis Harness A & B – 426 from M531064, 436 from M 533069
— Rear Cab Harness A & B – 426 from M531064, 436 from M 533069
— Rear Chassis Harness A – 426 from M531064, 436 from M 533069
— Rear Chassis Harness B – 426 from M531064, 436 from M 533069
— Side Console Harness A – 426 from M531064, 436 from M 533069
— Side Console Harness B – 426 from M531064, 436 from M 533069
— Cab Roof Harness A & B – 426 from M531064, 436 from M533069
— Front Chassis (HT) Harness – 426 from M531300, 436 from M533300, 446 form M540000
— Front Chassis (ZX) Harness – 426 from M531300, 436 from M533300, 446 from M540000
— Rear Chassis Harness – 426 from M531300, 436 from M533300
— Rear Chassis Harness – 426 from M531300, 436 from M533300
— Rear Chassis Harness – 446 from M540000
— Rear Chassis Harness – 446 from M540000
— Rear Chassis Harness – 426 from M531516, 436 from M533478
— Rear Chassis Harness – 426 from M531516, 436 from M533478
— Side Console Harness – 426 from M531516, 436 from M533478
— Side Console Harness – 426 from M531516, 436 from M533478
— Side Console Harness – 426 from M531516, 436 from M533478
— Rear Cab Harness – 426 from M531516, 436 from M533478
— Cab Roof Harness – 426 from M531516, 436 from M533478
— Controller Harness – 426 from M531516, 436 from M533478
— Rear Grille Harness – 426 from M531516, 436 from M533478
— Under Bonnet Harness – 426 from M531516, 436 from M533478
— Front Chassis Harness HT – 426 from M532100, 436 from M533692
— Front Chassis Harness ZX – 426 from M532100, 436 from M533692
— Rear Chassis Harness – 426 from M532100, 436 from M533692
— Side Console Harness – 426 from M532100, 436 from M533692
— Side Console Harness – 426 from M532100, 436 from M533692
— Side Console Harness – 426 from M532100, 436 from M533692
— Side Console Harness – Smoothshift
— Side Console Harness – Smoothshift
— Side Console Harness – Smoothshift
— Side Console Harness – Smoothshift
— Rear Cab Harness – 426 from M532100, 436 from M533692
— Cab Roof Harness – 426 from M532100, 436 from M533692
— Engine Harness – 426 from M532100, 436 from M533692
— Transmission Harness – 426 from M532100, 436 from M533692
— Canopy Harness – 426 from M532100, 436 from M533692
— Canopy Harness – 426 from M532100, 436 from M533692
— Canopy Harness – 426 from M532100, 436 from M533692
— Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
— Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
— Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
— Proportional Solenoid Harness – 426 from M532100, 436 from M533692
— Proportional Change Over Harness – 426 from M532100, 436 from M533692
— Bang – Bang Solenoid Harness – 426 from M532100, 436 from M533692
— Drawings and Interconnection
— Harnesses 426 from M1231500, 436 from M1305000
— Harnesses 426 from M1295000, 436 from M1410000
— Drawings
– Electronic Monitoring System
— System Identification
— General
— HC11 EMS
— Description
— Connecting up the Laptop
— Before Starting Service
— On completion of Service
— HC11 EMS – Software
— Installation
— Installation from Techweb
— Transfer New Program
— Serial Number
— Log Data
— Fault Limit Settings
— Connection of Interrogation Lead
— C164 EMS
— General
— EMS Tools
— Flash Loader Program
— Set-up Program
— Diagnostic Program
— Service History Program
— Data Logger Program
— Connecting the Interrogation Lead
– Alternator
— S11524-7 Alternator
— Removal and Replacement
— Dismantling and Assembling
— A5524 Alternator
— Dismantling
— Inspection, Testing and Repair
— Rotor
— Bearings
— Slip ring end bearing – Removal and Replacement
— Drive end bearing – Removal and Replacement
— Slip ring end housing – Removing Rectifier
— Refitting rectifier
— To remove and refit D+ and F- leads
— Brush holder assembly
— Stator and housing
— Re-assembly
— Testing
— Rectifier testing
— Testing
— Regulator Check
– Starter Motor
— 426 and 436 Machines
— Removal and Replacement
— Dismantling
— Servicing and Renewal
— Assembly
— 446 Machines
— Removal and Replacement
— Dismantling
— Cleaning
— Assembly
— Setting the Drive Pinion Clearance (446)
— No Load Test (446)
SectionE
– Hydraulics
– Technical Data
— 426 Machines up to Serial number 532099
— Pump
— Loader Valve
— 436, 446 Machines
— Primary Pump
— Secondary Pump
— Loader Valve
— Smoothshift Machines: 426 from serial number 532100, 436 from serial number 533692
— Pump
— Loader Valve
— Auxiliary Relief Valves (A.R.V.)
— 426 from Serial Number 532500, 436 from Serial Number 534200
— Pump
— Loader Valve
— Auxiliary Relief Valves (A.R.V.)
— 426 from Serial Number 532847, 436 from Serial Number 534469
— Pump
— Loader Valve
— Auxiliary Relief Valves (A.R.V.)
— Accumulators
— 426 from M1231500, 436 from M1305000
— Pump
— Loader Valve
— Auxiliary Relief Valve (ARV) Settings
— Accumulators
– Basic Operation
— General Description
— 426
— 436
— Valve Block Tie-Rods
— Introduction to Hydraulic Schematic Symbols
— General (Basic and Functional Symbols)
— Control Valves
— Example of Schematic Circuit
– Circuit Diagrams
— 426 to M531203, 436 to M533195
— 426 with 4-Ram Loader
— 426 with Z-Bar Loader
— 436 with 4-Ram Loader
— 436 with Z-Bar Loader
— 426 from M531204, 436 from M533196
— 426 with 4 Ram Loader
— 426 with Z-Bar Loader
— 436 with 4-Ram Loader
— 436 with Z-Bar Loader
— Smoothshift Machines (426 from M532100, 436 from M533692)
— 426, 436 with 4 Bar Loader
— 426, 436 with Z-Bar Loader
— 436 from M534200 (Tier II)
— 436 HT
— 436 ZX
— 426 from M532847
— 426 HT
— 426 ZX
— 436 from M534469
— 436 HT
— 436 ZX
— 426 from M1231500, 436 from M1305000
— Schematic Diagrams
– Circuit Descriptions
— Pump Operation
— Pump Pressure/Flow Regulator Valves
— Start Up
— Hydraulic Service Operated
— Minimum Flow/Maximum Pressure
— Start Up Valve
— Loader Valve
— Loader Valve – Arms Raise/Lower
— Loader Valve – Shovel Float
— Loader Valve – Shovel Tip (4-Ram Loader)
— Loader Valve – Shovel Crowd (4-Ram Loader)
— Loader Valve – Shovel Tip (Z-bar Loader)
— Loader Valve – Shovel Crowd (Z-bar Loader)
— Compensator Spool – Operation 1
— Compensator Spool – Operation 2
— Auxiliary Services
— Servo Pressure Regulating Valve
— Neutral Standby Pressure
— Service Operating
— Automatic Carry Control System (ACCS)
— Introduction
— Hydraulic Circuit
— Operation
— Maintenance Safety
— ACCS 426 from M1231500, 436 from M1305000
— General
— Circuit Descriptions
— Maintenance Safety
— Electronic Emergency Steering
— General
– Fault Finding
— Hydraulic Fault Finding
– Service Procedures
— Hydraulic Contamination
— Hydraulic Fluid Quality
— Effects of Contamination
— Cleaning Operation
— Contaminant Standards
— Filters
— Venting the Hydraulic Pressure
— 426 from M1231500, 436 from M1305000
— Automatic Carry Control System Venting
— Connecting and Disconnecting Hydraulic Hoses
— Connecting the Hoses
— Disconnecting the Hoses
— `Positional Type’ Hydraulic Adaptors
— Fitting Procedure
— Flow and Pressure Tests
— Main Pump – 426 Machines
— Main Pump – 436, 446 Machines
— Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump
— Tandem Pumps
— Servo Pressure – Tandem Pumps
— Steering Relief Valve
— Two-Stage Shovel Ram (Head Side)
— Idle Control Setting
— 426, 436 Machines
— Hydraulic Cooling Fan Setting
— 436 Machines to M1305000
— Reversing Fan Software
— Programming the Reversing Fan Frequency and Duration
— 426 Machines from M1231500, 436 Machines from M1235000
— Emergency Steering (Electronic)
— Checking/Adjusting the System Pressure
— Automatic Carry Control System (ACCS)
— Accumulators
— Dismantling, Inspection and Assembly
– Pumps
— 426 Machines Removal and Replacement
— When Removing
— When Replacing
— 436 Machines Removal and Replacement (Primary)
— When Removing
— When Replacing
— 436 Machines Removal and Replacement (Secondary)
— When Removing
— When Replacing
— Tandem Pumps – 426, 436
— General
— Removal and Replacement
— Replacing the Pressure/Flow Regulator
— Renewing Drive Shaft Seal
— Dismantling, Inspecting and Assembly
— Dismantling
— Inspecting
— Assembly
– Emergency Steering
— 426 from S/N 532847, 436 from S/N 534469
— Removal and Replacement
– Cooling Fan Motor
— 436 from M534200
— Removal and Replacement
— Replacement
— Dismantling, Inspection and Assembly
— 426 from 1231500, 436 from 1305000
— Removal
— Replacement
— Uni-Directional Motor
— Bi-Directional Motor
– Rams
— Precautions During Use
— Installation
— Caution During Use
— Maintenance, Inspection Points
— Typical Ram
— Dismantle and Assembly
— JCB Ram Sealing Procedure
— Piston Head Retention
— Z Rams
— Z Ram
— 436ZX Ram
— Dismantling the piston rod from cylinder tube
— Dismantling the piston rod
— Removing the piston seals
— Removing the cylinder head seals
— Assembling the piston seals
— Assembling the cylinder head seals
— Assembly of piston rod with cushion ring on the piston rod side
— Assembly of piston rod with cushion ring on the piston rod and cylinder bottom side
— Assembly of piston rod in cylinder tube
SectionF
– Transmission
– Technical Data
— 426 and 436
— Drive Axle – Front & Rear
— Transmission
– Powershift Transmission
— WG 150, WG 200
— Control Valve
— Charge Pump
— Coaxial Power Take-off
— Lateral Power Take-off
— Layshaft
— Final Drive
— Multi-Disc Clutches
— Clutch K4/K3
— Clutch KR/K2
— Clutch KV/K1
— Emergency Steering Pump
— WG 160, WG 190
— Main Components
— Oil Circulation Schematic
— Power Flow – Forward Speeds
— Power Flow – Reverse Speeds
— Test points and connections
— Electro-Hydraulic Shift Control
— Dismantling and Assembly
— Assembly
— Hydraulic Control Unit
– Fault Finding
— Functional Testing
— Semi – automatic
— Test Procedure (Automatic)
— Transmission Fault Finding
— Fault Codes (4WG-160/190/210)
– Service Procedures
— Electronic Monitoring System (EMS) Display Panel
– Removal and Replacement
— Replacement
— Replacement of Loader Arm Control Transmission Dump and Kickdown Switches
— Replacement of Wiring to Kick down and Transmission Dump Switches
— Removal and Replacement of Control Lever
– Propshafts
— Basic Operation
— Removing and Replacing
– Axles
— Front Axle
— Removal
— Replacement
— Rear Axle
— Removal
— Replacement
— Rear Axle – Heavy Duty
— Removal
— Replacement
— Hub and Driveshaft
— Dismantling
— Assembly
— Drive Head
— Dismantling
— Overhauling Pinion Bearing Support
— Pinion Depth
— Assembly
— Crown Wheel and Pinion
— Adjustment
— Correct Pattern
— Incorrect Pattern – High Contact
— Incorrect Pattern – Low Contact
— Limited Slip Differential Unit
— Dismantling
— Assembly
SectionG
– Brakes
— Brake Circuits
— Service Procedures
— Brake Valves
— Parking Brake
– Technical Data
— 446 (From Serial Number 540000 to 540011)
— 426/436
– Brake Circuits
— 426 To Serial Number 532099, 436 to Serial Number 533691, 446 from Serial No. 540000 to 540011
— 426 From Serial Number 532100, 436 from Serial Number 533692
— 436 From Serial Number 534200 (Tier II)
– Service Procedures
— Service Brakes
— System Testing
— 436 from Serial No. 534200 – (Tier II, with Hydraulic Engine Cooling Fan
— Brake Pressure Setting
— Bleeding the System
— System Accumulators
— Charging the Accumulators
— Parking Brake (Type 1)
— Adjusting the Parking Brake
— Adjusting the Brake Pads
— Adjusting the Cable Slack
— Renewing the Brake Pads
— Parking Brake (Type 2)
— Adjusting the Parking Brake
— Adjusting the Cable Slack
— Renewing the Brake Pads
— Park Brake Testing
— Pre Smoothshift Machines
— Smoothshift Machines
– Brake Valves
— Foot Valve
— Removal and Replacement
— Dismantling and Assembly
– Parking Brake
— Type 1
— Dismantling and Assembly
— Type 2
— Dismantling
— Assembly
SectionH
– Hydraulic Steering
– Technical Data
— General data
— Pump
– Circuit Descriptions
— Steering Operations
— General Description
— Steering Valve – Operation
– Hydraulic Steering Unit
— Dismantling and Assembly
— Dismantling
— Inspecting
— Assembling
– Emergency Steering Pump
— Dismantling and Assembly
— When Dismantling
— When Assembling
SectionK
– Engine
– Technical Data
— 426 and 436
— 446
— 426B and 436B
— 426 from Serial No. 532500
— 436 from Serial No. 534200
— 426e from Serial No. 1295000
— 436e from Serial No. 1410000
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