JCB 446, 456 Wheeled Loading Shovel Service Manual – 9803/4180-08

This workshop repair service manual PDF download for the 446, 456 JCB Wheeled Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheeled Loading Shovel 456 – from machine serial number 539000
JCB Wheeled Loading Shovel 446 – from machine serial number 540000

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/4180-08
Total Pages : 1038

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-4180
Service Manual

Section 1 – General Information
General Information
Introduction
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
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference Section
Section B – Body and Framework
Section C – Electrics
Section E- Hydraulics
Section F – Transmission
Section G – Brakes
Service Aids
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes
Black and White Codes
Basic Operation
Preparation for Towing

Section 2 – Care and Safety
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 Labels
Introduction
Safety Label Identification
Part Numbers and Descriptions

Section 3 – Routine Maintenance
Routine Maintenance
Routine Maintenance
Service Requirements
Introduction
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
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Introduction
446 from 540000, 456 to 1169000
456 from 1169000, 446 from 1181000
Coolant Mixtures
Anti-Corrosion Additives
Fuel
Tools
Toolbox
Carrying Tools onto the Machine
Prepare the Machine for Maintenance
Introduction
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
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Seat and Seat Belt
Check the Tyres
Check the Hydraulic Hoses and Fittings
Checking the ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Greasing – 446 and 456 to 1169000
Greasing – 456 from 1169000
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
Engine Covers
Rear Grille
Heater Door
Air Conditioning
Adjusting the Compressor Belt – 446, 456 to 1169000
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
Battery
Jump Starting The Engine
Fuses and Relays
Engine
Oil and Filter
Cooling System
Drive Belt
Air Filter
Fuel System
Introduction
Draining the Fuel Filter
Changing the Fuel Filter Element
Draining the Sedimenter Bowl
Cleaning the Sedimenter Bowl
Bleeding the System
Fuel System 4546e Only
Draining the Fuel Filter
Changing the Suction Side Fuel Filter Element
Changing the Pressure Side Fuel Filter Element
Bleeding the System
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
446 and 456 to 1169000
456 from 1169000
Transmission
446 and 456 to 1169000
456 from 1169000
Axles
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Windscreen Washers
446 to 540049, 456 to 539399
446 from 540050, 456 from 539400 to 1169000
456 from 1169000
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A – Attachments
Attachments
Optional Attachments
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Quickhitch
Removal and Installation
Removal
Installation
Quickhitch Ram
Removal and Installation
Removal
Installation

Section B – Body and Framework
Body and Framework
Technical Data
Air Conditioning Option
Cab
Glazing
Direct Glazing
ROPS/FOPS Structure
Checking
456 from 1169129, 446 from 1181004
Removal and Replacement
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 the Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Pressure Switch Assembly
Condenser
Adjusting the Compressor Drive Belt
Air Conditioning
Early Type
The Air Conditioning Unit
The Blower Unit
Thermostat
Evaporator
Later Type
The Air Conditioning Unit
The Blower Motor
Thermostat
Evaporator
456 from 1169000, 446 from 1181000
The Air Conditioning Unit
Filters
Blower Motor
Thermostat
Evaporator
Expansion Valve
Heater Radiator
Binary Pressure Switch
Cooling Pack
Removal and Replacement – 446 and 456 to 1168999
Introduction
Removal and Replacement
Dismantling and Assembly – 446 and 456 to 1168999
Dismantling
Assembly
Removal and Replacement – 456 from 1169000
Introduction
Removal
Hydraulic Cooling Fan
Removal and Installation
Removal
Installation
Bleeding Procedure
Cooling Fan Motor
Removal And Replacement
Machines to 116900
456 from 1169000
456 from 1169129, 446 from 1181004
Dismantling, Inspection and Assembly
456 from 1169000
456 from 1169129, 446 from 1181004 Uni- Directional Motor
456 from 1169129, 446 from 1181004 Bi- Directional Motor
Heater/Air Conditioning Controls
Removal and Installation
Removal
Installation
Centre Pivot
Removal and Replacement
Removal
Replacement
Bodywork
Removal and Replacement of the Rear Bodywork
Removal
Replacement

Section C – Electrics
Electrics
Technical Data
Electrical Data
General
Bulbs
Fuses and Relays to 539228 (456)
Fuses
Relays
Fuses and Relays from 540013 (446), 539229 (456)
Fuses
Primary Fuses
Relays
Diagnostic Connectors
Fuses and Relays from 540107 (446), 539486 (456)
Fuses
Primary Fuses
Relays
Diagnostic Connectors
Fuses and Relays from 1169000 (456), 1181000 (446)
Fuses and Relays
Fuses and Relays 456e
Fuses and Relays
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
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
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Fault Finding
Introduction to Fault – Finding Techniques
Harness Routing
Example of Wire Tracing
Schematic Circuits
To 539228 (456)
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
From 540013 (446), 539662 (456)
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Main Components
Fuses
Main Components
Fuses
Main Components
Fuses
Electronic Emergency Steering from 540120 (446), 539662 (456)
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Return to Dig Operation from 540100 (446), 539402 (456)
Main Components
Lamps
Fuses
456 from 1169000, 446 from 1181000
Primary Fuses, Ignition Switch and Ignition Relays
Instrumentation
ZF Computer and Gearbox Controller
Front Wipe, Rear Wipe and Heater/AC
Front and Rear Work Lights and Beacon
Roadlights
Radio, Power Sockets, CCTV and Tow Hitch
ESOS, Mirrors, Seats, Reverse Fan and Emergency Steer
12 Volt Trailer Electrics and Loader Functions
Loader Auxiliaries (Proportional)
Tier 3 Engine ECU (ECM)
Earthing
Options
456e Machines
Basic Circuit
Harness Data
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
Wire and Harness Identification from 540013 (446), 539229 (456)
Front Chassis Harness HT
Front Chassis Harness ZX
Rear Chassis Harness
Side Console Harness
Rear Cab Harness
Cab Roof Harness
Engine Harness
Transmission Harness
Canopy Harness
Canopy Fuse Box Harness
Wire and Harness Identification
Harnesses From 1169000 (456), 1181000 (446)
Harnesses 456e (Tier 3)
Drawings
Electronic Monitoring System
System Identification
General
HC11 EMS
HC11 Display Panel
Description
Connecting the Laptop
Before Starting the Service
On Completion of Service
HC11 EMS Software
C164 EMS
C164 Display Panel
General
EMS Tools
Flash Loader Program
Set-up Program
Diagnostic Program
Service History Program
Data Logger Program
Connecting the Interrogation Lead

Section E – Hydraulics
Hydraulics
Technical Data
456 Dual Pump
Primary Pump
Secondary Pump
Loader Valve
446 Dual Pump
Pump
Loader Valve
446 Tandem Pump
Pump
Loader Valve
Auxiliary Relief Valves
456 Tandem Pump
Pump
Loader Valve
Auxiliary Relief Valves
456 from 1169000 Tandem Pump
Pumps
Loader Valve
Auxiliary Relief Valves
456 from 1169129, 446 from 1181004
Pumps
Loader Valve
Auxiliary Relief Valves
Basic Operation
General Description
Valve Block Tie-Rods
Introduction to Hydraulic Schematic Symbols
General (Basic & Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
456 to 539249
Component Key
446 from 540013 and 456 from 539250
Component Key
446 from 540120 and 456 from 539662
Component Key
456 from 1169000 and 446 from 1181000
Component Key
456 from 1169129 and 446 from 1181004
Component Key
456 Machines with a Parker Valve
456HT
456ZX
Descriptions
Pump Operation
Pump Pressure/Flow Regulator Valves
Start Up
Hydraulic Service Operated
Minimum Flow/Maximum Pressure
Start Up Valve
Loader Valve – Operation
Loader Valve 456 from 1169000
3-Spool Loader valves
3-Spool HT Loader Valve from 1169000
3-Spool ZX Loader Valve from 1169000
Automatic Carry Control System
Introduction
Hydraulic Circuit
Operation
Maintenance Safety
456 from 1169129, 446 from 1181004
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Venting the Hydraulic Pressure
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
456 to 1169000
456 from 1169000
456 from 11169129, 446 from 1181004
Automatic Carry Control System
Accumulators
Dismantling, Inspection and Assembly
Cooling Fan Motor
Removal And Replacement
Dismantling, Inspection and Assembly: 456 from 1169000
Dismantling, Inspection and Assembly: 456 from 1169000
Uni-Directional Motor 456 from 1169129, 446 from 1181004
Bi-Directional Motor 456 from 1169129, 446 from 1181004
Emergency Steering
446 from 540120, 456 from 539662
Fault Finding
General
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Typical Ram
Typical Ram
Hydraulic Rams
Introduction
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
Engine Driven Gear Pump
Dismantling, Inspection and Assembly
Introduction
Routine Maintenance
Direction of Rotation
Dismantling
Inspection
Assembly
Servo Control Lever
Removal and Installation
Removal
Installation
Servo Valve
Removal and Installation
Removal
Installation
SRS Control Valve
Removal and Installation
Removal
Installation
SRS Accumulators
Removal and Installation
Removal
Installation

Section F – Transmission
Transmission
Technical Data
Axles 456
Unit Identification
Axles
Transmission
Axles 446
Axles
Transmission
Axles
Front Axle
Introduction
Removal
Replacement
Rear Axle
Removal
Replacement
Rear Axle – Heavy Duty
Introduction
Removal
Replacement
Hub and Driveshaft
Dismantling
Assembly
Drive Head – Standard
Dismantling
Overhaul Pinion Bearing Support (PR15 and PR24 Rear Axles)
Pinion Depth
Assembly
Limited Slip Differential Unit
Dismantling
Overhauling Pinion Bearing Support
Assembly
Crown Wheel and Pinion
Adjustment
Correct Pattern
Incorrect Pattern – High Contact
Incorrect Pattern – Low Contact
Driveshafts
Removing and Replacing
Powershift Transmission
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 Steer Pump
WG 210
Main Components
Oil Circulation Schematic
Power Flow – Forward Speeds
Power Flow – Reverse Speeds
Test Points and Connections
Electro-Hydraulic Shift Control
Dismantling
Assembly
Hydraulic Control Unit
Functional Testing
Introduction
General
Automatic
Transmission Fault Finding
Fault Codes (4WG-210)
Electronic Monitoring System Display Panel

Section G – Brakes
Brakes
Technical Data
446 and 456
Schematic Diagrams
Brake Circuit 456 to 539249
Brake Circuit (446 from 540013 and 456 from 539250)
Service Procedures
456 To 539249
Testing the Park Brake
456 From 539250
Testing the Park Brake
Pre-Smoothshift Transmission
Testing the Park Brake
Smoothshift Transmission
Testing the Park Brake
446
Adjusting the Park Brake
Adjusting the Cable Slack
Bleeding the Brake System
Accumulators
Brake Circuits, Valves and Pedals
Brake Valve
System Testing
Removal and Replacement
Dismantling and Assembly
Brake Pressure Setting
Park Brake To 539249 (456)
Removal and Replacement
Dismantling and Assembly
Adjusting the Pads
Checking the Pad Wear
Renewing the Pads
Park Brake From 539250 (456)
Removal and Replacement
Dismantling and Assembly
Adjusting the Pads
Checking the Pad Wear
Changing the Pads
Park Brake 446
Dismantling
Assembly
Renewing the Brake Pads

Section H – Steering
Steering
Technical Data
Pump
General Description
Descriptions
Steering Valve – Operation
Emergency Steering – Operation
Hydraulic Steering Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspecting
Assembly
Emergency Steering Pump
Dismantling and Assembly
When Dismantling
When Assembling
Emergency Steering
446 from 540120, 456 from 539662
General
Checking/Adjusting the System Pressure
Removal and Replacement
Steering Column
Removal and Installation
Removal
Installation

Section K – Engine
Engine
Technical Data
446 (Before 1181000) and 456 (Before 1169000)
446 (From 1181000) and 456e (From 1169000)

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