JCB 446, 456 Wheeled Loading Shovel Service Manual
1,255 pages · Publication 9803-4180-11
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- Models
- 446, 456 Wheeled
- Serial coverage
- 456 from SN 539000, 446 from SN 540013
- Manual type
- Service Manual
- Pages
- 1,255
- Publication
- 9803-4180-11
- Condition
- Brand new
What's inside
From the manual's own table of contents: 5 sections, 437 entries. See sample pages (PDF, 449 KB)
General76 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
- Typical Vehicle Identification Number
- Typical Product Identification Number
- 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
- Section B - Body and Framework
- Section C - Electrics
- Section E- Hydraulics
- Section F - Transmission
- Section G - Brakes
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Black and White Codes
- Preparation for Towing
- 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
- Service Schedule 456 from 1239000
- Fluids, Lubricants and Capacities
- 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 Arms 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
Section 3 - Routine Maintenance91 topics
- Loader Arms and Shovel
- Centre Pivot, Rear Axle Pivots and Steer Rams
- Cab Door Hinges
- Driveshafts
- Quickhitch Locking-Pins
- Automatic Greasing System (if fitted)
- Access Panels
- Engine Covers
- Rear Grille
- Heater Door
- Air Conditioning
- Adjusting the Compressor Belt - 456 from 1169000
- Cab Heater Filters
- Cleaning the Intake Filter (Early Machines)
- Cleaning the Intake Filter (Later Machines)
- Cleaning the Recirculation Filters to 539249
- Cleaning the Intake Filter (Smoothshift Machines)
- Cleaning the Recirculation Filter (Smoothshift Machines)
- Cleaning the Intake Filter - 456 from 116900
- Cleaning the Recirculation Filter - 456 from 1169000
- Brakes
- Park Brake
- Service Brake
- Electrical System
- Fuses and Relays
- Jump Starting The Engine
- Engine
- Oil and Filter
- Cooling System
- Drive Belt
- Air Filter
- Fuel System
- Draining the Fuel Filter
- Changing the Fuel Filter Element
- Draining the Sedimenter Bowl
- Cleaning the Sedimenter Bowl
- Bleeding the System
- Fuel System 4546e Only
- Changing the Suction Side Fuel Filter Element
- Changing the Pressure Side Fuel Filter Element
- 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
- R134a Refrigerant
- System Operation
- System Control
- Safety Procedures
- Visual Inspection
- System Diagnosis
- Rivet Nuts
- Fitting Procedure
- Checking the Refrigerant Charge Level
- Leak Testing
- Tightening Leaking Hoses
- Refrigerant Charging and Discharging
- Pressure Switch Assembly
- Condenser
- Adjusting the Compressor Drive Belt
- Early Type
- The Air Conditioning Unit
- The Blower Unit
- Thermostat
- Evaporator
- Later Type
- The Blower Motor
- Air Conditioning Unit
- Filters
- Blower Motor
- Expansion Valve
- Heater Radiator
- Binary Pressure Switch
- Removal and Replacement
- Dismantling and Assembly - 446 and 456 to 1168999
- Dismantling
- Assembly
Section B - Body and Framework39 topics
- Removal and Replacement - 456 from 1169000
- Cleaning the Cooling Pack
- Bleeding Procedure
- Machines to 116900
- Dismantling, Inspection and Assembly
- Replacement
- Glazing
- Direct Glazing
- ROPS/FOPS Structure
- Checking
- Removal and Replacement of the Rear Bodywork
- Inspection
- Electrical Data
- General
- Bulbs
- Fuses
- Relays
- Primary Fuses
- Diagnostic Connectors
- Fuses and Relays 456e from 1304000
- Introduction to Fault - Finding Techniques
- Harness Routing
- Example of Wire Tracing
- System Identification
- 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
Section C - Electrics93 topics
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- 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
- Main Components
- Lamps
- Summary of Changes
- Instrumentation (C164)
- ZF Computer and Gearbox Controller
- Tier 3 Engine ECU (ECM)
- Front Wipe, Rear Wipe and Heater/Air Conditioning
- Front and Rear Work Lights and Beacon
- Roadlights
- Radio, Power Sockets, CCTV and Tow Hitch
- ESOS, Mirrors, Seats, Reverse Fan and Emergency Steer
- 12V Trailer Electrics and Loader Functions
- Loader Auxiliaries (Proportional)
- Earthing
- Options
- 456e Machines
- Basic Circuit
- T2 and T3 for New Cab Instruments
- Primary Fuses, Ignition Switch and Ignition Relays
- Instrumentation
- Management ECU
- ZF Transmission Controller
- Tier 2 and 3 Engine ECU (ECM)
- Front Wipe, Rear Wipe, Heater, A/C or Climate Control
- Radio, Power Sockets and CCTV
- Immobiliser, Seats, Autolube, Steering and Bucket/Fork
- Trailer Electrics and CANBUS
- Wire and Harness Identification to 539228 (456)
- Connector Location and Identification
- Front Chassis Harness
- Rear Chassis Harness
- Side Console Harness
- Rear Cab Harness
- Cab Roof Harness
- Controller Harness
- Rear Grille Harness
- Hydraulic Mode Harness
- Under Bonnet Harness
- Front Chassis Harness HT
- Front Chassis Harness ZX
- Engine Harness
- Transmission Harness
- Canopy Harness
- Canopy Fuse Box Harness
- Wire and Harness Identification
- Drawings
- Harnesses for the 457
- Disassembly
- Lucas Type
- Dual Pump
- Primary Pump
- Secondary Pump
- Loader Valve
- Dual Pump
- Pump
- Tandem Pump
- Auxiliary Relief Valves
- Tandem Pump
- from 1169000 Tandem Pump
- Pumps
- Valve Block Tie-Rods
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Intentionally Blank
- Component Key
- Machines with a Parker Valve
- Pump Operation
- Pump Pressure/Flow Regulator Valves
- Start Up
- Hydraulic Service Operated
- Minimum Flow/Maximum Pressure
Section E - Hydraulics87 topics
- Start Up Valve
- Loader Valve - Operation
- 3-Spool Loader Valves
- 3-Spool HT Loader Valve from 1169000
- 3-Spool ZX Loader Valve from 1169000
- Smooth Ride System
- Hydraulic Circuit
- Operation
- Parker Valve
- 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 Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Venting the Smooth Ride System
- Pressure Testing (Dual Pumps Pre-Smoothshift)
- Pump Pressure Testing
- Pressure Testing (Smoothshift - Tandem Pumps)
- Standby Pressure
- Checking the Main Pressure
- Checking the Servo Pressure
- Pressure Testing Steering Relief Valve
- ARV Pressure Testing
- Pressure Testing Using a Hand Pump
- Checking And Setting The Hydraulic Fan Speed
- Accumulators
- Cooling Fan Motor
- Dismantling, Inspection and Assembly 456 from 1169000
- Emergency Steering
- Routine Maintenance
- Direction of Rotation
- Precautions During Use
- Caution During Use
- Maintenance, Inspection Points
- Typical Ram
- Hydraulic Rams
- Dismantling the Piston Rod from Cylinder Tube
- Dismantling the Piston Rod
- Removing the Piston Seals
- Removing the Cylinder Head Seals
- Assembly of Piston Seals
- Assembling the Cylinder Head Seals
- Assembly of Piston Rod
- Assembly of Piston Rod in Cylinder Tube
- JCB Ram Sealing Procedure
- Loader Lift/Crowd Rams
- Lift Ram
- Crowd Ram (HT)
- De-Pressuring the Smooth Ride System
- Hot Test Settings
- T2 ZF Axles
- 456e T3 ZF Axles
- Axles 456
- Unit Identification
- Axles 446
- Front Axle
- Rear Axle
- Rear Axle - Heavy Duty
- Hub and Driveshaft
- Drive Head - Standard
- Overhaul Pinion Bearing Support (PR15 and PR24 Rear Axles)
- Pinion Depth
- Limited Slip Differential Unit
- Overhauling Pinion Bearing Support
- Crown Wheel and Pinion
- Adjustment
- Correct Pattern
- Incorrect Pattern - High Contact
- Incorrect Pattern - Low Contact
- Removing and Replacing
- 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 Steer Pump
Section F - Transmission46 topics
- Oil Circulation Schematic
- Power Flow - Forward Speeds
- Power Flow - Reverse Speeds
- Test Points and Connections
- Electro-Hydraulic Shift Control
- Hydraulic Control Unit
- Automatic
- Transmission Fault Finding
- ZF Error Codes
- Electronic Monitoring System Display Panel
- Identification Plate
- Contact Patterns
- Output Shaft and Brake
- Axle Housing
- Input Pinion
- Differential
- Input
- Output and Brake
- Testing the Park Brake
- Pre-Smoothshift Transmission
- Smoothshift Transmission
- Adjusting the Park Brake
- Adjusting the Cable Slack
- Bleeding the Brake System
- Brake Valve
- System Testing
- Dismantling and Assembly
- Brake Pressure Setting
- Adjusting the Pads
- Checking the Pad Wear
- Renewing the Pads
- Changing the Pads
- Park Brake 446
- Renewing the Brake Pads
- Steering Valve - Operation
- Emergency Steering - Operation
- Dismantling and Assembly - Type 1
- Exploded View
- Inspecting
- Dismantling and Assembly - Type 2
- Special Tool
- Checking/Adjusting the System Pressure
- When Dismantling
- When Assembling
- Possible faults
- Components
Inside this manual
Real pages from this service manual (1,255 pages). Open the sample pages (PDF, 449 KB)
- Diagram, page 623: Harness Data
- Specifications, page 984: Section F - Transmission
- Troubleshooting, page 1,098: Section F - Transmission
- Color page, page 488: Section C - Electrics
- Color page, page 277: Section B - Body & Framework
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, 1,255 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
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).