JCB 426, 435, 436, 446 Wheeled Loading Shovel Service Manual
1,366 pages · Publication 9803-4160-17
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- Models
- 426, 435, 436, 446 Wheeled
- Serial coverage
- 426 from SN 531001, 427 from SN 533001, 435 from SN 533001, 436 from SN 533001, 437 from SN 533001, 446 from SN 540000 to 540011
- Manual type
- Service Manual
- Pages
- 1,366
- Publication
- 9803-4160-17
- Condition
- Brand new
What's inside
From the manual's own table of contents: 5 sections, 458 entries. See sample pages (PDF, 430 KB)
General83 topics
- About this Manual
- Machine Model and Serial Number
- Using the Service Manual
- Section Numbering
- Left Side, Right Side
- Cross References
- Identifying Your Machine
- Machine Identification Plate
- Component Identification Plates
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- Numerical List
- Tool Detail Reference
- Section B - Body and Framework
- Section C - Electrics
- Section E- Hydraulics
- Section F - Transmission
- Section H - Steering
- Section K - Engine
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Labels
- Safety Label Identification
- Part Numbers and Descriptions
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Initial Service and Inspection
- Fit for Purpose Tests for Lifting Equipment
- Obtaining Replacement Parts
- Health and Safety
- Lubricants
- Battery
- Service Schedules
- How to Use the Service Schedules
- Calendar Equivalents
- Fluids, Lubricants and Capacities
- Specifications
- Coolant Mixtures
- Anti-Corrosion Additives
- Fuel
- Tools
- Toolbox
- Carrying Tools onto the Machine
- Prepare the Machine for Maintenance
- How to Make the Machine Safe (Loader Arm Lowered)
- How to Make the Machine Safe (Loader Arms Lifted)
- Safety Mechanism
- Articulation Lock
- Cleaning the Machine
- Preparing the Machine for Cleaning
- Checking for Damage
- Check the Machine Body and Structure
- Check the Seat and Seat Belt
- Check the Tyres
- Check the Electrical Circuits
- Check the Hydraulic Hoses and Fittings
- Checking the ROPS/FOPS Structure
- Greasing
- Preparing the Machine for Greasing
- Loader Arms and Shovel
- Centre Pivot, Rear Axle Pivots and Steer Rams
- Quickhitch Locking-Pins
- Cab Door Hinges
- Driveshafts
- Automatic Greasing System (if fitted)
- Access Panels
- Rear Grille
- Heater Door
- Engine Covers
Section 3 - Routine Maintenance67 topics
- Heater and Air Conditioning
- Cleaning the Air Intake Filter
- Cleaning the Re-Circulation Filter (if fitted)
- Adjusting the Compressor Belt
- Brakes
- Park Brake
- Service Brake
- Electrical System
- Battery Isolator Switch
- Fuses and Relays
- Jump Starting The Engine
- Engine
- Air Filter
- Cooling System
- Fan Belts
- Fuel System
- Standard System
- Hydraulic System
- Releasing the Hydraulic Pressure
- Transmission
- Axles
- ZF Axles
- Tyres and Wheels
- Tyre Inflation
- Checking the Wheel Nut Torques
- Windscreen Washers
- Fire Extinguisher (if fitted)
- Checking the Fire Extinguisher
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hydraulic Hoses
- Disconnecting the Hydraulic Hoses
- Quick Release Couplings
- Removal and Installation
- Removal
- Installation
- Air Conditioning Option
- Air Conditioning
- R134a Refrigerant
- System Operation
- System Control
- Safety Procedures
- Visual Inspection
- System Diagnosis
- Rivet Nuts
- Fitting Procedure
- 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
- Early Type
- The Air Conditioning Unit
- The Blower Unit
- Thermostat
- Evaporator
- Pressure Switches
- Later Type
- The Blower Motor
- Filters
- Blower Motor
- Expansion Valve
- Heater Radiator
- Binary Pressure Switch
- Removal and Replacement
- Dismantling and Assembly
Section B - Body and Framework41 topics
- Cleaning the Cooling Pack
- Motor
- Bleeding
- Glazing
- Direct Glazing
- ROP/FOPS Structure
- Inspection
- General Electrical Data
- Light Bulbs
- Introduction to Fault - Finding Techniques
- Harness Routing
- Example of Wire Tracing
- Component Testing
- Tier 3 EMS
- General
- HC11 EMS
- HC11 Display Panel
- Description
- Connecting the Laptop
- Before Starting Service
- On Completion of Service
- HC11 EMS - Software
- C164 Display Panel
- EMS Tools
- Flash Loader Program
- Set-up Program
- Diagnostic Program
- Service History Program
- Data Logger Program
- Connecting the Interrogation Lead
- Tier 4 EMS
- Instrument Cluster Setup
- Management ECU Setup
- Machine Data Logger
- Machine Diagnostics
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
Section C - Electrics90 topics
- Maintenance
- First Aid - Electrolyte
- Testing
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starter Motor
- Starting Circuit Test
- Wire and Harness Number Identification
- Wire Numbers and Functions
- Wiring Harness Repair
- Repair Procedure
- from March ‘98
- Machines - Italian Military Only
- Primary Fuses, Ignition Switch and Ignition Relays
- Instrumentation
- ZF Computer and Gearbox Controller
- Front Wipe, Rear Wipe, Heater/AC and Heated Screen
- Front and Rear Worklights and Beacon
- Roadlights
- Radio, Cigar Lighter, CCTV and Tow Hitch
- ESOS, Mirrors, Seats, Reverse Fan and Emergency Steer
- 12V Trailer Electrics and Loader Functions
- Loader Auxiliaries (Proportional)
- Earthing - Cab and Cab Roof
- Earthing - Front and Rear Chassis
- Instrumentation (C164)
- Tier 3 Engine ECU (ECM)
- Front Wipe, Rear Wipe and Heater/Air Conditioning
- Front and Rear Work Lights and Beacon
- Radio, Power Sockets, CCTV and Tow Hitch
- Earthing
- Options
- ZF Transmission Controller
- Radio, Power Socket, Auxiliary Socket, LiveLink and CCTV
- Immobiliser, Heated Mirrors And Seat, Emergency Steer, Autolube, Bucket/Fork C
- Trailer Electrics and CANBUS
- Engine ECU
- Cummins QSB and QSL T4i
- Connector Location and Identification
- Harness Drawings
- Front Chassis
- Side Console - Smoothshift
- Drawings
- S11524-7 Alternator
- 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
- Rectifier Testing
- Regulator Check
- and 436 Machines
- Servicing and Renewal
- Assembly
- Machines
- Cleaning
- Setting the Drive Pinion Clearance (446)
- No Load Test (446)
- Pump
- Loader Valve
- Primary Pump
- Secondary Pump
- Auxiliary Relief Valves
- Accumulators
- Parker Valve
- Auxiliary Relief Valve Settings
- Valve Block Tie-Rods
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Intentionally Blank
- with 4-Ram Loader
- with Z-Bar Loader
- with 4-Ram Loader
- with Z-Bar Loader
- with 4 Ram Loader
Section E - Hydraulics121 topics
- Schematic Diagrams
- HT M250 Valve Block
- Pump Operation
- Pump Pressure/Flow Regulator Valves
- Start Up
- Hydraulic Service Operated
- Minimum Flow/Maximum Pressure
- Start Up 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
- Smooth Ride System
- Hydraulic Circuit
- Operation
- Electronic Emergency Steering
- 4-Spool ZX Valve
- 4-Spool HT Valve
- 3-Spool ZX Valve
- 3-Spool Proportional ZX Valve
- 3-Spool Proportional HT Valve
- 3-Spool HT Valve
- Hydraulic Fault Finding
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Venting the Smooth Ride System
- Positional Type Hydraulic Adaptors
- Flow and Pressure Tests
- Pressure Testing the Loader ARVs Using a Hand Pump
- Tandem Pumps
- Servo Pressure - Tandem Pumps
- Steering Relief Valve
- Two-Stage Shovel Ram (Head Side)
- Idle Control Setting
- Hydraulic Cooling Fan Setting
- Reversing Fan Software
- Programming the Reversing Fan Frequency and Duration
- Emergency Steering (Electronic)
- Checking/Adjusting the System Pressure
- Dismantling, Inspection and Assembly
- Cooling Fan Motor
- Removal and Replacement
- When Removing
- When Replacing
- Removal and Replacement (Primary)
- Removal and Replacement (Secondary)
- Replacing the Pressure/Flow Regulator
- Renewing Drive Shaft Seal
- Dismantling, Inspecting and Assembly
- Inspecting
- Precautions During Use
- Caution During Use
- Maintenance, Inspection Points
- Typical Ram
- Dismantle and Assembly
- Piston Head Retention
- JCB Ram Sealing Procedure
- Z Rams
- 436ZX Ram
- Dismantling the Piston Rod from the 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
- Assembly of the Piston Rod in the Cylinder Tube
- Loader Lift/Crowd Rams
- Lift Ram
- Crowd Ram (HT)
- De-Pressuring the Smooth Ride System
- Hot Test Settings
- T2 Hydraulic Fan ZF Axles
- 426e T3 160QSB Hydraulic Fan ZF Axles
- 426e T3 Agri ZF Axles
- T2 ZF Axles
- 436e T3 173QSB Agri ZF Axles
- Drive Axle - Front and Rear
- 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
- Main Components
- Oil Circulation Schematic
- Power Flow - Forward Speeds
- Power Flow - Reverse Speeds
- Test Points and Connections
- Electro-Hydraulic Shift Control
- Hydraulic Control Unit
- Front Axle
- Replacement
- Rear Axle
- Rear Axle - Heavy Duty
- Hub and Driveshaft
- Drive Head
- Overhauling Pinion Bearing Support
- Pinion Depth
- Crown Wheel and Pinion
- Adjustment
- Correct Pattern
- Incorrect Pattern - High Contact
- Incorrect Pattern - Low Contact
- Limited Slip Differential Unit
Section F - Transmission51 topics
- Removing and Replacing
- Identification Plate
- Contact Patterns
- Output and Brake
- Axle Housing
- Input
- Differentials
- Output Shaft and Brake
- Input Pinion
- Differential
- General Information
- Automatic
- Semi-Automatic
- Transmission Fault Finding
- Drive/Gear Selection Status Lights
- Definition of Operating Modes
- ZF Controller Plug
- Wiring to Kickdown and Transmission Dump Switches
- Removal and Replacement of Control Lever
- Electronic Monitoring System Display Panel
- Service Brakes
- System Testing
- from 534200 - (Tier II, with Hydraulic Engine Cooling Fan
- Brake Pressure Setting
- Bleeding the System
- Park Brake Testing
- Pre Smoothshift Machines
- Smoothshift Machines
- Park Brake (Type 1)
- Adjusting the Park Brake
- Adjusting the Brake Pads
- Adjusting the Cable Slack
- Renewing the Brake Pads
- Park Brake (Type 2)
- Park Brake Switch
- Park Brake Lever
- Park Brake Cable
- Park Brake Caliper
- Park Brake Pads
- System Accumulators
- Charging the Accumulators
- Park Brake Type 1
- Park Brake Type 2
- Foot Brake Valve
- Steering Operations
- Steering Valve - Operation
- Emergency Steering Operation
- Assembling
- When Dismantling
- When Assembling
- Possible faults
Inside this manual
Real pages from this service manual (1,366 pages). Open the sample pages (PDF, 429 KB)
- Troubleshooting, page 225: Section B - Body and Framework
- Diagram, page 645: Harness and Wire Number Identification
- Specifications, page 1,023: Section F - Transmission
- Color page, page 535: Section C - Electrics
- Color page, page 1,117: Section F - Transmission
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,366 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).