jcb 446 User manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/4180-11
Publication No.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]
Service Manual
Wheeled Loading Shovel - 446, 456
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

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/4180-08
Publication No.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]
Section 1
General Information
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Section A
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
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Section 1 - General Information
1 - 0 1 - 0
9803/4180-08
Notes:
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Page No.Contents
Section 1 - General Information
1 - i 1 - i
Introduction
About this Manual .................................................................................... 1 - 1
Machine Model and Serial Number .................................................... 1 - 1
Using the Service Manual .................................................................. 1 - 1
Section Numbering ............................................................................. 1 - 1
Left Side, Right Side ........................................................................... 1 - 2
Cross References ............................................................................... 1 - 2
Identifying your Machine .......................................................................... 1 - 3
Machine Identification Plate ............................................................... 1 - 3
Typical Vehicle Identification Number ................................................. 1 - 3
Typical Product Identification Number ................................................ 1 - 4
Component Identification Plates ......................................................... 1 - 5
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 7
Introduction ......................................................................................... 1 - 7
Bolts and Screws ................................................................................ 1 - 7
Hydraulic Connections ........................................................................... 1 - 11
'O' Ring Face Seal System ............................................................... 1 - 11
'Torque Stop' Hose System .............................................................. 1 - 14
Service Tools
Numerical List ........................................................................................ 1 - 15
Tool Detail Reference Section ............................................................... 1 - 16
Section B - Body and Framework ..................................................... 1 - 16
Section C - Electrics ......................................................................... 1 - 21
Section E- Hydraulics ....................................................................... 1 - 23
Section F - Transmission .................................................................. 1 - 25
Section G - Brakes ........................................................................... 1 - 28
Service Aids
Sealing and Retaining Compounds ....................................................... 1 - 29
Terms and Definitions
Colour Coding ........................................................................................ 1 - 31
Hydraulic Schematic Colour Codes .................................................. 1 - 31
Black and White Codes .................................................................... 1 - 32
Basic Operation
Preparation for Towing ........................................................................... 1 - 33
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Page No.Contents
Section 1 - General Information
1 - ii 1 - ii
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Section 1 - General Information
1 - 1 1 - 1
9803/4180-08
Introduction
About this Manual
Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– 456 Wheeled Loading Shovel from 539000
– 446 Wheeled Loading Shovel from 540013.
Using the Service Manual
T11-004
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.
General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.
Where a torque setting is given as a single figure it may be
varied by plus or minus 3%. Torque figures indicated are
for dry threads, hence for lubricated threads may be
reduced by one third.
The manufacturer's policy is one of continuous
improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
Finally, please remember above all else safety must come
first!
Section Numbering
T11-005
The manual is compiled in sections, the first three are
numbered and contain information as follows:
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
1General Information - includes torque settings and
service tools.
2Care and Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.
3Maintenance - includes service schedules and
recommended lubricants for all the machine.
AAttachments
BBody and Framework, etc.
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Section 1 - General Information
Introduction
About this Manual
1 - 2 1 - 2
9803/4180-08
Left Side, Right Side
In this manual, 'left' Aand 'right' Bmean your left and right
when you are seated correctly in the machine.
T033800-1
Fig 1.
Cross References
T1-004_2
In this publication, page cross references are made by
presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K Cross
References ( T 1-2).
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Section 1 - General Information
Introduction
Identifying your Machine
1 - 3 1 - 3
9803/4180-08
Identifying your Machine
Machine Identification Plate
Your machine has an identification plate mounted as
shown. The serial numbers of the machine and its major
units are stamped on the plate.
Note: The machine model and build specification is
indicated by the PIN. Refer to Typical Product
Identification Number (PIN).
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.
The machine and engine serial numbers can help identify
exactly the type of equipment you have.
T033550-2
Fig 2.
Typical Vehicle Identification Number
1World Manufacturer Identification, SLP = JCB
2Machine Model, 456ZX
3Year of Manufacture (P = 1993, R = 1994, S = 1995,
T = 1996, V = 1997, W = 1998, X = 1999, Y = 2000, 1
= 2001, 2 = 2002, 3 = 2003, 4 = 2004)
4Manufacturers Location (E = England)
5Machine Serial Number (0539001)
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.
The machine and engine serial numbers can help identify
exactly the type of equipment you have.
1234 5
SLP 456 V E 539000
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Section 1 - General Information
Introduction
Identifying your Machine
1 - 4 1 - 4
9803/4180-08
Typical Product Identification Number
T033160-1.
Fig 3.
1World Manufacturer Identification (3 Digits)
2Model Number (3 Digits)
3Loader End Type (1 Digit)
4Designation (1 Digit)
5Check Letter (1 Digit)
The Check Letter is used to verify the authenticity of
the machine’s PIN.
6Year of Manufacture (1 Digit)
7Machine Serial Number (7 Digits)
Each machine has a unique serial number.
Note: On later models, the year of manufacture digit was
removed and the machine serial number was increased to
8 digits.
O = HT Loader End
Z = ZX Loader End
S = Farmmaster
O = None Farmmaster
I = India
7 = 2007 A = 2010
8 = 2008 B = 2011
9 = 2009 C = 2012
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Section 1 - General Information
Introduction
Identifying your Machine
1 - 5 1 - 5
9803/4180-08
Component Identification Plates
Unit Identification
Fig 4.
The engine serial number is stamped on a plate 4Y which
is fastened to the right side of the cylinder block.
Fig 5.
The transmission serial number is stamped on plate 5Z as
shown.
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Section 1 - General Information
Introduction
Identifying your Machine
1 - 6 1 - 6
9803/4180-08
FOPS Data Plate
!MWARNING
Do not use the machine if the falling objects protection
level provided by the structure is not sufficient for the
application. Falling objects can cause serious injury.
8-2-8-17
If the machine is used in any application where there is a
risk of falling objects then a falling-objects protective
structure (FOPS) must be installed. For further information
contact your JCB Dealer
The fallingobjects protection structure (FOPS) is fittedwith
a dataplate. The dataplate indicates what level protection
the structure provides.
There are two levels of FOPS:
–Level I Impact Protection - impact strength for
protection from small falling objects (e.g. bricks, small
concrete blocks, hand tools) encountered in
operations such as highway maintenance,
landscaping and other construction site services.
–Level II Impact Protection - impact strength for
protection from heavy falling objects (e.g. trees,
rocks) for machines involved in site clearing,
overhead demolition or forestry.
ROPS Data Plate
!MWARNING
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
!MWARNING
Seat Belts
The ROPS/FOPS is designed to give you protection in
an accident. If you do not wear your seat belt, you
could be thrown out of the machine and crushed. You
must wear a seat belt when using the machine. Fasten
the seat belt before starting the engine.
0153
Machines built to the ROPS/FOPS standard have a data
plate attached to the inside of the cab.
332-A5586
Fig 6.
J.C.B.CAB SYSTEMS
LAKESIDE WORKS
ROCESTER
UTTOXETER,STAFFS
ST14 5JP
ENGLAND
427
437
457
FOPS:
COMPLIES TO
EN 13627:2000
LEVEL2
CAB PART No:
335/06840,335/09298
YEAR:
SERIAL No:
MAXIMUM UNLADEN
MASS 26000Kg
JCB WHEELED LOADER ROPS:
COMPLIES TO
EN 13510:2000
ISO 3471:1994
332/A5586

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1 - 7 1 - 7
9803/4180-08
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
T11-002
Introduction
Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on
earlier machines.
The two types of fasteners can be readily identified by
colour and part number suffix. K Table 1. Fastener Types
(T 1-7).
Table 1. Fastener Types
Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.
Note: A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. For the
same reason, a Dacromet nut should not be used with a
Zinc or Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur.
Dacromet bolts are only used for external applications.
They are not used in applications such as gearbox or
engine joint seams or internal applications.
Bolts and Screws
Use the following torque setting tables only where no
torque setting is specified in the text.
Note: Dacromet fasteners are lubricated as part of the
plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
– Un-lubricated fasteners
– Zinc fasteners
– Yellow plated fasteners
Condition 2
– Zinc flake (Dacromet) fasteners
– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example,
cast iron components
Verbus Ripp Bolts
Fig 7.
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Fastener
Type Colour Part No. Suffix
Zinc and
Yellow Golden finish 'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1 - 8 1 - 8
9803/4180-08
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
Bolt Size Hexagon (A/F) Condition 1 Condition 2
in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft
1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4
5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7
3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5
7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0
1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9
9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9
5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5
3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9
7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9
1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9
1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0
1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3
Bolt Size Hexagon (A/F) Condition 1 Condition 2
ISO Metric
Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6
M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1 - 9 1 - 9
9803/4180-08
Table 4. Metric Grade 10.9 Fasteners
Table 5. Metric Grade 12.9 Fasteners
Bolt Size Hexagon (A/F) Condition 1 Condition 2
ISO Metric
Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4
M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2
M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2
M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6
M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1
M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2
Bolt Size Hexagon (A/F) Condition 1 Condition 2
ISO Metric
Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5
M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1
M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7

Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1 - 10 1 - 10
9803/4180-08
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Bolt Size
Nm kgf m lbf ft
ISO Metric
Thread mm
M3 3 1.2 0.1 0.9
M4 4 3.0 0.3 2.0
M5 5 6.0 0.6 4.5
M6 6 10.0 1.0 7.5
M8 8 24.0 2.5 18.0
M10 10 48.0 4.9 35.5
M12 12 82.0 8.4 60.5
Bolt Size
Nm kgf m lbf ft
ISO Metric
Thread
M3 2.0 0.2 1.5
M4 6.0 0.6 4.5
M5 11.0 1.1 8.0
M6 19.0 1.9 14.0
M8 46.0 4.7 34.0
M10 91.0 9.3 67.0
M12 159.0 16.2 117.0
M16 395.0 40.0 292.0
M18 550.0 56.0 406.0
M20 770.0 79.0 568.0
M24 1332.0 136.0 983.0

Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
1 - 11 1 - 11
9803/4180-08
Hydraulic Connections
T11-003
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an 'O' ring
which is compressed into a 45° seat machined into the
face of the tapped port.
Table 8. Torque Settings - BSP Adaptors
Table 9. Torque Settings - SAE Connections
BSP Adaptor
Size Hexagon (A/F)
Nm kgf m lbf ftin. mm
1/4 19.0 18.0 1.8 13.0
3/8 22.0 31.0 3.2 23.0
1/2 27.0 49.0 5.0 36.0
5/8 30.0 60.0 6.1 44.0
3/4 32.0 81.0 8.2 60.0
1 38.0 129.0 13.1 95.0
1 1/4 50.0 206.0 21.0 152.0
SAE Tube
Size SAE Port Thread Size
Hexagon (A/F)
Nm kgf m lbf ftmm
4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0
8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0

Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
1 - 12 1 - 12
9803/4180-08
Hoses Screwed into Adaptors
Fig 8.
Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring
8-C which is compressed into a 45° seat machined into the
face of the adaptor port.
Note: Dimension 8-D will vary depending upon the torque
applied.
Table 10. BSP Hose - Torque Settings
BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ftin. mm
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8

Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
1 - 13 1 - 13
9803/4180-08
Adaptors into Component Connections with Bonded Washers
Table 11. BSP Adaptors with Bonded Washers - Torque Settings
BSP Size
Nm kgf m lbf ftin.
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0

Section 1 - General Information
Standard Torque Settings
Hydraulic Connections
1 - 14 1 - 14
9803/4180-08
'Torque Stop' Hose System
Fig 9.
`Torque Stop' Hoses 9-B screwed into adaptors 9-A seal
onto an 'O' ring 9-C which is compressed into a 45° seat
machined in the face of the adaptor port. To prevent the 'O'
ring being damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 9-D, which acts
as a physical stop.
Note: Minimum dimension 9-E fixed by shoulder 9-D.
Table 12. BSP `Torque Stop' Hose - Torque Settings
BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ftin. mm
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0

Section 1 - General Information
1 - 15 1 - 15
9803/4180-08
Service Tools
Numerical List
The tools listed in the table are special tools required for
carrying out the procedures described in this manual.
These tools are available from JCB Service.
Some tools are available as kits or sets, the part numbers
for parts within such kits or sets are not listed here. For full
details of all tools, including the content of kits and sets,
refer to Tool Detail Reference, Section 1.
Note: Tools other than those listed will be required. It is
expected that such general tools will be available in any
well equipped workshop or be available locally from any
good tool supplier.