jcb 426 Operator's Manual
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jcb 426 Operator's Manual

jcb 426 Operator's Manual

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OPERATOR'S MANUAL
426, 436, 456 (TIER 2)
EN - 9811/3400
ISSUE 4 - 06/2017
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

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  • Page 1 OPERATOR'S MANUAL 426, 436, 456 (TIER 2) EN - 9811/3400 ISSUE 4 - 06/2017 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...
  • Page 3 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. A4-9-WLS - Printed In England...
  • Page 4 Notes: 9811-3400...

  • Page 5: Table Of Contents

    Left Side, Right Side ................. 1 Cab/Canopy ..................... 1 Cross References ..................1 Machine Description ..................2 The JCB Wheeled Loader ................ 2 Intended Use .................... 2 Component Location ................2 Safety Check List ................... 4 Safety - Yours and Others ................ 4 General Safety ..................
  • Page 6 Contents Contents Page No. Drive Controls, Switches and Instruments ........... 36 Drive Controls ..................36 Switches ....................42 Instrument Panel ..................48 Heater/Air Conditioning Controls ............55 Operating Levers ..................56 Introduction ..................... 56 Control Layouts ..................56 Loader Arm Controls ................57 Auxiliary Controls ...................
  • Page 7 Contents Contents Page No. Storage of the Machine ................92 Introduction ..................... 92 Storage Area ..................92 Prepare the Machine for Storage ............92 Put the Machine into Storage ..............92 During Storage ..................92 Take the Machine Out of Storage ............93 Routine Maintenance Service Requirements .................
  • Page 8 Contents Contents Page No. Access Panels ................... 131 Rear Grille .................... 131 Heater Door ..................131 Engine Covers ..................132 Heater and Air Conditioning ..............133 Cleaning the Air Intake Filter ..............133 Cleaning the Re-Circulation Filter (if fitted) .......... 134 Adjusting the Compressor Belt .............
  • Page 9 Noise Data ....................206 Introduction ................... 206 All Machines ..................206 Vibration Data .................... 207 Introduction ................... 207 Specifications ..................207 426, 436 ....................208 456 ....................... 209 Warranty Information Machine Service Record Sheet ..............211 Registration Information ................213...
  • Page 10 Contents Contents Page No.

  • Page 11: Safety Notices

    Operator Manual. If you do not other operators. understand anything, ask your employer or JCB dealer to explain it. In this publication and on the machine, there are safety INT-1-4-2 notices.
  • Page 12 Safety Notices Important Information Page left intentionally blank 9811-3400-4...

  • Page 13: Introduction

    T033800-1 Fig 1. aspects of operating and maintaining the machine. Cab/Canopy If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could T1-003_2 be killed or seriously injured. This manual frequently makes references to the cab. For...

  • Page 14: Machine Description

    Hydraulic fluid filler point (456) in areas with dust containing asbestos, special safety regulations must be followed and the machine must be Hydraulic fluid tank sight glass (426/436) equipped for use in these environments. Hydraulic fluid tank sight glass (456)
  • Page 15 Introduction Machine Description 10, 11 812110-2 Fig 2. Component locations 9811-3400-4...

  • Page 16: Safety Check List

    JCB distributor to explain them. with it. If you don't, you will not do your job well, and you will be a danger to yourself and others.
  • Page 17 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.

  • Page 18: Operating Safety

    Introduction Safety Check List Operating Safety WARNING Work Sites WARNING Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the Machine Condition ground gives way under your machine or if piled A defective machine can injure you or others.
  • Page 19 Do not lights, windows and mirrors clean. machine potentially explosive atmosphere, i.e. combustible vapours, gas or dust, Do not operate the machine if you cannot see clearly. without first consulting your JCB Distributor. 5-1-4-7 INT-2-1-14 WARNING CAUTION Electrical Power Cables Regulations...
  • Page 20 5-5-1-1_2 WARNING WARNING High Loads Use only the JCB approved attachments that are A high load can block your view and reduce the specified for your machine. Operating with non- machine's stability. Travel with the load low to the specified attachments can overload the machine, ground.

  • Page 21: Maintenance Safety

    Introduction Safety Check List Maintenance Safety WARNING Fires WARNING If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct Communications machine location until you need to use it. Bad communications can cause accidents. If two or more people are working on the machine, make sure Do not use water to put out a machine fire, you could each is aware of what the others are doing.
  • Page 22 Introduction Safety Check List WARNING CAUTION Fluid Under Pressure It is illegal to pollute drains, sewers or the ground. Fine jets of fluid at high pressure can penetrate the Clean up all spilt fluids and/or lubricants. skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves.
  • Page 23 CAUTION WARNING 'O' rings, Seals and Gaskets Certain seals and gaskets (e.g. crankshaft oil seal) on Badly fitted, damaged or rotted 'O' rings, seals and JCB machines contain fluoroelastomeric materials gaskets can cause leakages and possible accidents. such Viton, Fluorel Technoflon.
  • Page 24 Prior to any work being carried out on systems incorporating accumulators, the system HYD-1-3_2 pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may WARNING cause injury.
  • Page 25 Introduction Safety Check List DANGER WARNING Electrolyte Wheels and tyres are heavy. Take care when lifting or Battery electrolyte is toxic and corrosive. Do not moving them. breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and Store with care to ensure that they cannot fall and eyes.

  • Page 26: Safety Labels

    Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor. 9811-3400-4...

  • Page 27: Safety Label Identification

    Introduction Safety Labels Safety Label Identification The position of the safety labels attached to a typical machine are as shown. ISO-05C ISO-04A (x2) ISO-13A (x2) ISO-02C ISO-07D (x2) ISO-07C (x2) ISO-01A ISO-06B ISO-10A ISO-12B ISO-06C ISO-09F T010560-8 Fig 3. Safety label locations 9811-3400-4...

  • Page 28: Part Numbers And Descriptions

    Introduction Safety Labels Part Numbers and Descriptions ISO-05C Part Number: 332/P7129 ISO-01A Description: Runover. Start the engine from the operator Part Number: 817/70014 seat only. Do not short across the terminals. Description: Warning. Read operator manual before you operate the machine. 332-P7129-1 817-70014-3 ISO-06B...
  • Page 29 Introduction Safety Labels ISO-07D ISO-13A Part Number: 817/70027 Part Number: 332/P7134 Description: Crush hazard. Keep a Description: Entanglement hazard. Do not touch. safe distance from the moving parts. 817-70027-2 332-P7134-1 ISO-09F Part Number: 332/P7132 Description: Severing of hands or fingers. Keep clear of/ do not reach into the moving parts.

  • Page 30: Identifying Your Machine

    Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Typical Product Identification Number 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 T033160-1.

  • Page 31: Component Identification Plates

    If the machine is used in any application where there is a risk of falling objects then a falling-objects protective INT-2-1-9_6 structure (FOPS) must be installed. For further information contact your JCB Dealer WARNING Seat Belts The falling objects protection structure (FOPS) is fitted with The ROPS/FOPS is designed to give you protection in a dataplate.

  • Page 32: Machine Security

    JCB is doing everything possible logged onto the CESAR or DVLA databases, and a change to help combat this. of keeper form. Your JCB Distributor or Dealer will be pleased to provide information on any of these sensible precautions. ACT NOW! JCB Plantguard JCB PLANTGUARD is a comprehensive package available to help you safeguard your machine.

  • Page 33: Introduction

    Do not guess. If there is anything you do not understand, ask your JCB distributor. The operator must always be aware of events happening in or around the machine. Safety must always be the most important factor when you operate the machine.

  • Page 34: Before Entering The Cab

    Operation Before Entering the Cab Before Entering the Cab T2-025_4 The following checks should be made each time you return d Inspect the windows for cracks and damage. to the machine after leaving it for any period of time. We Glass splinters can blind.

  • Page 35: Entering And Leaving The Cab

    Operation Entering and Leaving the Cab Entering and Leaving the Cab WARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry.

  • Page 36: Emergency Exit

    Operation Entering and Leaving the Cab Emergency Exit Glazing Breaker (if fitted) In an emergency if the door cannot be used: If the machine has a glazing breaker C, it is possible to use the side window as an emergency exit. Open the right side window (emergency exit) as far as the retaining-strut A will allow.

  • Page 37: Doors And Windows

    Operation Doors and Windows Doors and Windows Opening and Closing the Door Opening and Closing the Right Side Window P4-2001 To open the door from the outside, unlock it with the key provided and press the lock barrel. To open the window: Close the door from the inside by pulling it firmly: it will Turn the handle C 90 clockwise.

  • Page 38: Seat Controls

    Operation Seat Controls Seat Controls Introduction Suspension Seat (Type 1) T2-007_3 Note: Adjustments should only be made by the operator WARNING when sat on the seat. Seat Horizontal Adjustment (Slide rails) Position the seat so that you can comfortably reach the machine controls.

  • Page 39: Air Suspension Seat

    Operation Seat Controls Air Suspension Seat Fore/Aft Isolator Adjustment: P7-2005 To enable the fore/aft suspension movement of the Adjustments should only be made by the operator when seat, move the lever 4 to the forward position. (For sat on the seat. example when you move across rough ground or tow a trailer).

  • Page 40: Console Arm Rest

    Operation Seat Controls Lumbar Support Adjustment (Option): Console Arm Rest P4-2030 Seat Type 1: Operate the two switches 9 until the Introduction lower part of your back is comfortably supported. The position of the arm rest can be adjusted to give the Seat Type 2: Turn the knob 9 until the lower part of operator a comfortable and supportive position to move your back is comfortably supported.

  • Page 41: Seat Belt

    Operation Seat Belt Seat Belt Inertia Reel Seat Belt the belt too sharply or if the machine is parked on an incline. In such cases, ease the belt gently from its reel T2-001_2 holder. WARNING Check the Seat Belt is Operating Correctly If you do not wear your seat belt you could be thrown about inside the machine, or thrown out of the Sit correctly in the seat and fasten the seat belt as...

  • Page 42: Visibility Aids

    Operation Visibility Aids Visibility Aids Mirrors Adjusting the Mirror T2-054 Adjust the seat to suit the operator. Introduction Adjust the mirror(s) to suit your specific working When operating the machine the operator must continually requirements before you drive or operate the survey their field of vision.
  • Page 43 Operation Visibility Aids Checking the Field of Vision Rear View Mirror Check that the field of vision A at ground level shall be such that you can see, using the mirror(s), at least a 10 metre (X) wide flat, horizontal portion of the ground, centred on the vertical longitudinal median plane of the machine, 30 metre (Y) behind the rear end of the machine Field of vision...
  • Page 44 Operation Visibility Aids Side Mirrors Check that the field of vision A is such that you can see, using the mirrors at least a flat portion bounded on the left and right of the machine, starting at the rear end of the machine at a height of 1 metre above ground level and a width of 0.75 metres (Z), continuing to a width of 3.5 metres (X) at ground level, 30 metres (Y) behind the rear...
  • Page 45 Operation Visibility Aids Page left intentionally blank 9811-3400-4...

  • Page 46: Cab Layout

    Operation Cab Layout Cab Layout Component Key The cab component layout illustration shows a typical machine. Your machine may look different to the model shown. km/h 6,7,14 797710-1 Fig 21. 9811-3400-4...
  • Page 47 K Foot Brake Pedal ( T 36) K Transmission Kickdown Switch ( T 42) K Transmission Dump Switch ( T 42) K Park Brake Lever (426, 436 Only) ( T 37) K Park Brake Switch (456 Only) ( T 37) K Instrument Panel ( T 48)

  • Page 48: Drive Controls, Switches And Instruments

    Operation Drive Controls, Switches and Instruments Drive Controls, Switches and Instruments Drive Controls Turn the lever A in a clockwise direction to lock the steering column in position. Steering Wheel Note: The locked position of lever A can be altered - pull T2-048 the lever out and move to the required position.
  • Page 49 Operation Drive Controls, Switches and Instruments Park Brake Lever (426, 436 Only) Park Brake Switch (456 Only) CAUTION CAUTION The park brake must not be used to slow the machine The park brake must not be used to slow the machine...
  • Page 50 Operation Drive Controls, Switches and Instruments Transmission Forward/Reverse Switch The forward/reverse switch A is used to control the Forward/Reverse Lever and Transmission Control direction of the machine as an alternative to the forward/ reverse lever. Forward Neutral To select a drive direction move the switch to the required position.
  • Page 51 Operation Drive Controls, Switches and Instruments Drive Selection WARNING You and others can be killed or injured if you operate the forward/reverse lever while you travel. The machine will immediately reverse direction without warning others. Follow recommended procedure for proper use of this selector. 2-2-2-4_2 WARNING Travelling at High Speeds...
  • Page 52 Operation Drive Controls, Switches and Instruments Transmission Modes Table 1. 4-Speed Manual Mode (A/M Switch OFF) Barrel Forward Reverse Kickdown To ensure selection of the most applicable gear ratio and Position shift points for a given machine application, the operator None can select one of two transmission modes.
  • Page 53 Operation Drive Controls, Switches and Instruments Table 3. 6-Speed Manual Mode (A/M Switch OFF) Table 5. 4-Speed Clutch Engagement Barrel Forward Reverse Kickdown Barrel Forward Reverse Position Position F1, R1 KV K1 KR K1 3rd only 2nd only None KV K2 KR K2 4th only 3rd only...

  • Page 54: Switches

    Operation Drive Controls, Switches and Instruments Switches Console Switches Introduction General SW-001_2 The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol A to show the function of the switch. Before you operate a switch, make sure that you understand its function.
  • Page 55 Operation Drive Controls, Switches and Instruments Left Console Switches Right Console Switches Quickhitch Locking Pin Isolator (if fitted) Rear Window Wiper (if fitted) Two position rocker switch (spring- Three position rocker switch. The switch loaded). The switch functions operate functions operate when the starter switch when the starter switch is in the ON is in the ON position.
  • Page 56 Operation Drive Controls, Switches and Instruments Auxiliary Hydraulic Circuit Changeover (if fitted) Cigar Lighter Two position rocker switch with backlight. Push the knob until it latches, do not hold The switch functions operate when the the knob in the pushed position. The knob starter switch is in the ON position.
  • Page 57 Operation Drive Controls, Switches and Instruments Roof Panel Switches Heated Seat (if fitted) Two position rocker switch with backlight. WARNING The switch functions operate when the starter switch is in the ON position. Do not drive on the road with the work lights switched on.
  • Page 58 Operation Drive Controls, Switches and Instruments Multi-Purpose Steering Column Switch Horn Push the button to operate the horn. It functions only Turn Signals (Right) with the starter switch set to on. Pull the lever towards you to indicate a right turn. Switch the turn signals off when you have completed the turn.
  • Page 59 Operation Drive Controls, Switches and Instruments Starter Switch Cab Interior Light T2-050 T2-020 This is a rotary switch, operated by the starter key. It has Press either end of the light unit A to switch on the cab four positions. The key can be removed only with the interior light.

  • Page 60: Instrument Panel

    Operation Drive Controls, Switches and Instruments Instrument Panel Introduction P4-2019 794940-1 Fig 32. The instruments and indicator lights are grouped together Digital Display on an instrument panel. K Fig 32. ( T 48). Instruments As well as indicator lights for the direction indicators, main beam etc.
  • Page 61 Operation Drive Controls, Switches and Instruments Instruments P4-2016 794940-2 Fig 33. Fuel Gauge Indicates the level of fuel in the tank. Do not let the tank run dry, or air will enter the fuel system. Note: The message "LOW FUEL" is displayed on the panel when only 10% of fuel is left in the tank.
  • Page 62 Operation Drive Controls, Switches and Instruments Digital Display P4-2017 794940-4 Fig 34. Ignition On CAUTION All the warning lights should go out when the engine is started. Rectify any faults immediately. 4-2-1-4 During the first second after switching on, all LCD segments and warning lights are illuminated then the software version is displayed on the top line.
  • Page 63 Operation Drive Controls, Switches and Instruments System Faults (Error Message Only) Setting Up Error messages are displayed on the top line of the display Turn on the power by turning the starter key to IGN. panel. Pressing the SETUP/SELECT button while in Pre- –...
  • Page 64 The Service Required is reset when initiate the automatic engine shut down system. Refer to data is down loaded by your JCB Dealer. Automatic Engine Shut Down. When lit, warning lights shown with an a hash (#) will...
  • Page 65 Operation Drive Controls, Switches and Instruments Hydraulic Fluid Temperature High 19# Emergency Steer Pump Audible/Visual with Message "HYD OIL TEMP" Visual with Message "EM STEER FAULT" displayed on the top line of the display panel. displayed on the top line of the display panel. Lights Operates if the hydraulic fluid temperature rises too up when the emergency steering system is high.
  • Page 66 Operation Drive Controls, Switches and Instruments Automatic Engine Shut Down The following warnings will also initiate the automatic engine shut down system. Engine Oil Pressure Low (7) Transmission Oil Temperature High (10) Brake System Pressure Low (21) Main Steer System (22) Water Temperature High (23) Air Filter Blocked (24) A 30 second count down to engine shut down starts as...

  • Page 67: Heater/Air Conditioning Controls

    Operation Drive Controls, Switches and Instruments Heater/Air Conditioning Controls Fan. Turn the switch to start the three-speed heater fan. Turn the switch more to get faster fan speeds. The fan operates only with the starter key in the IGN position. Temperature.

  • Page 68: Operating Levers

    Operation Operating Levers Operating Levers Introduction Control Layouts P4-2011_3 WARNING WARNING Controls Control lever/switch action may vary on machines, You or others can be killed or seriously injured if you decals near the levers/switches show by symbols, operate the control levers from outside the machine. which levers/switches cause what actions.

  • Page 69: Loader Arm Controls

    Operation Operating Levers Loader Arm Controls Multi-Control Levers The information label is adjacent to the multi-controls levers. 817-20024-2 Fig 37. Loader arms raise Loader arms lower Loader arms float. Push the multi-control lever forward as far as it will go and leave it there Shovel dump 806610-4 Shovel crowd...
  • Page 70 Operation Operating Levers Servo-Control Lever with Auxiliary Lever The information label is adjacent to the servo-control lever. 806610-6 Fig 39. Loader arms raise Loader arms lower Loader arms float. Push the servo-control lever forward as far as it will go and leave it there Shovel dump Shovel crowd 806610-1...
  • Page 71 Operation Operating Levers Servo-Control Lever with Auxiliary Buttons The information label is adjacent to the servo-control lever. 817-17584 Fig 41. Loader arms raise Loader arms lower Loader arms float. Push the servo-control lever forward as far as it will go and leave it there. Shovel dump T005700-4 Shovel crowd...

  • Page 72: Auxiliary Controls

    Operation Operating Levers Auxiliary Controls WARNING Before operating the Auxiliary control system make sure that you are aware of all WARNINGS and CAUTIONS that apply to the attachment you are using. Also make sure you have fitted the attachment correctly. (See OPTIONAL ATTACHMENT section). 5-2-2-6 CAUTION If you have an optional attachment which is not...

  • Page 73: Safety Equipment

    Operation Safety Equipment Safety Equipment Control Lever Locks Neutral Lock P4-2008 Loader Arm Control Isolator Switch CAUTION Do not operate the Forward/Reverse switch when To prevent the hydraulic loader arm controls from being already using the Forward/Reverse lever, otherwise operated accidentally when the driver is entering or leaving the transmission will select neutral.

  • Page 74: Fire Extinguisher (If Fitted)

    Operation Safety Equipment Fire Extinguisher (if fitted) If the circumstances permit and your safety is not endangered, move the machine to a safe place to prevent the fire from spreading. Location Remove extinguisher from its stowage bracket. The fire extinguisher is found inside the operator cab and is held in position by a stowage bracket.

  • Page 75: Beacon

    Operation Safety Equipment Beacon Note: We recommend that you install a beacon before you travel on public highways. In certain territories you will be breaking the law if you do not install a beacon before you travel on public highways, make sure you are complying with local laws.

  • Page 76: Before Starting The Engine

    Inspect the ROPS/FOPS structure for damage. CAUTION Get your JCB Distributor to repair any damage. On machines fitted with hose burst protection valves Make sure all its securing bolts are fitted and the attachments cannot be lowered with the engine correctly tightened.
  • Page 77 Operation Before Starting the Engine Adjust the seat so that you can comfortably reach all the driving controls. You should be able to apply full brake pedal travel with your back against the seat back. If fitted, adjust the armrest so that you can reach and operate the controls without stretching.

  • Page 78: Starting The Engine

    Operation Starting the Engine Starting the Engine P4-2009 until the oil pressure low light has gone out. Check WARNING that the audible alarm is silent. Exhaust Gases Note: The engine noise and or tone may be louder than Breathing the machine exhaust gases can harm and usual when cold.

  • Page 79: Preparing The Machine For Travel

    Important: While this information is believed to be correct, JCB cannot be aware of all circumstances in which the JCB machine may be operated on a Public Highway and it is the responsibility of the user to ensure compliance with the regulations.

  • Page 80: Preparing For Site Travel

    Operation Preparing the Machine for Travel Preparing for Site Travel Automatic Carry Control System - (if fitted) Read and understand the information given in Preparing the Machine for Travel. The Automatic Carry Control System (ACCS) is a hydraulic suspension system that is designed to supply a "cushion"...

  • Page 81: Getting The Machine Moving

    Operation Getting the Machine Moving Getting the Machine Moving Operating Practices WARNING Should the machine start to roll over, you can be WARNING crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Do not let the machine coast with the transmission in Stay in the cab, with your seat belt fastened.

  • Page 82: Operating Procedure

    If you are 2-2-2-4_2 not sure, assume that they are defective and contact the nearest JCB Dealer. Make sure the loader arm is in the travel position. Push the brake pedal. Select forward or reverse drive.

  • Page 83: Stopping And Parking The Machine

    Operation Stopping and Parking the Machine Stopping and Parking the Machine P4-2012 Operate the control lever to lower the shovel/ WARNING attachments to the ground. Once they are on the ground, operate the controls a little further so that it Parking begins to take the weight of the machine.

  • Page 84: Working With The Machine

    The information in this section is given in good faith and in light of the best information available, JCB can accept no responsibility recommendations,...

  • Page 85: Danger Zone

    Operation Working with the Machine cause serious injury to yourself and damage the machine. WARNING Contact your JCB dealer. Underground Gas Pipes Clothing and Safety Equipment Before you start using the machine, check with your local gas company if there are any buried gas pipes on T2-069 the site.

  • Page 86: Working With A Shovel

    Operation Working with the Machine Working with a Shovel Filling the Shovel P4-2015_2 WARNING When loading with material from a high bank or pile, remove any overhang first. Watch out for sliding material. If overhanging material falls, you and your machine could be buried.
  • Page 87 Operation Working with the Machine Loading a Truck T2-004_2 Put the truck(s) at an angle of about 45° to the pile, as shown. This cuts out unnecessary manoeuvring. Allow enough distance for the shovel to reach its unloading height while you are travelling, without slowing down. Keep the wind on your back.

  • Page 88: Working On Slopes

    Operation Working with the Machine Working on Slopes Driving Up and Down Slopes P4-2014 Introduction WARNING Slopes WARNING When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase Hillsides stability. Operating the machine on hillsides can be dangerous if proper precautions are not taken.
  • Page 89 Operation Working with the Machine Lifting Operations on Slopes WARNING Conducting lifting operations on gradients can be dangerous. The machine can become laterally unstable and tip over if the instructions in this section are not followed and understood. You and others can be seriously injured or killed.

  • Page 90: Machine Adjustments

    Operation Working with the Machine Machine Adjustments Introduction The machines have a loader arms lift re-set proximity- switch and can have an optional shovel re-set proximity- switch. The loader arms re-set proximity-switch releases the control lever detent at a pre-determined angle when the loader arms are being lifted.
  • Page 91 Operation Working with the Machine Set the Attachment Angle Proximity-Switch HL, HT, SHL Machines Park the machine on hard, level ground. Refer to Stopping and Parking the Machine. Loosen the locknuts F, then adjust the bar D, so that its end is aligned with the proximity-switch X. 456HT machines have two proximity-switches.
  • Page 92 Operation Working with the Machine ZX Machines Park the machine on hard, level ground. Refer to Stopping and Parking the Machine. Set the shovel to the angle required, with the shovel on the ground. Loosen the bolts F, then adjust the bar D, so that its end is aligned with the proximity-switch E.

  • Page 93: Object Lifting

    INT-1-3-7_2 For more information on this section, consult your local JCB Distributor, also refer to Fit for Purpose Tests for Lifting Equipment. Note: In certain countries Safety Regulations in force call for the application of specific safety factors. Consult your local JCB Distributor for information.
  • Page 94 Operation Working with the Machine Safe Working Loads P11-5001_3 WARNING The safe working load shown on lifting accessories (for example chains, etc.) is not the safe working load of the machine. M0002 The maximum load which may be lifted depends on the equipment fitted to the machine and the laws and regulations in force at the time and in the country in which the machine is being used.

  • Page 95: Operating Environment

    -18°C (0°F) and below, additional starting aids may be needed. Examples are fuel, oil and coolant heaters. Ask your JCB distributor for advice. Important: Do not connect additional batteries in series to give more than 24V for starting, only connect slave batteries in parallel.

  • Page 96: Operating In Coastal Regions

    Operation Operating Environment Operating in Coastal Regions Cab Filters Check that all the plugs, bolts and fasteners are all There are three different filters available for the cab heater tightened correctly. unit/air-conditioning unit. After daily operations, clean the machine thoroughly Important: The cab is pressurised, in dusty conditions the and take special care when cleaning the electrical doors and windows should be closed and ventilation...

  • Page 97: Refuelling The Machine

    If air enters the fuel system, the engine speed will vary CAUTION dramatically and low power will be experienced. The symptoms may be made worse when the machine Consult your fuel supplier or JCB distributor about the operates on steep gradients. suitability of any fuel you are unsure of. GEN-9-2...
  • Page 98 Operation Refuelling the Machine CAUTION Spilt fuel may cause skidding and therefore accidents. Clean any spilt fuel immediately. Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. INT-2-2-12 At the end of every working day, fill the tank with the correct type of fuel.

  • Page 99: Moving A Disabled Machine

    The machine can be lifted onto a trailer for transportation. CAUTION However, you must contact the nearest JCB Dealer before you try to tow, winch or push the machine. Towing, Towing a machine too far or too fast can damage the winching or pushing the machine without following the transmission.
  • Page 100 Operation Moving a Disabled Machine The machine is now ready for towing. Make sure you When the steering wheel is turned, the pump is heard understand what the towing driver will be doing. Obey his running and the articulation of the chassis is felt. Test the instructions and all relevant regulations.

  • Page 101: Transporting The Machine

    Operation Transporting the Machine Transporting the Machine When the machine is safely in position, lower the WARNING attachment onto the trailer, then stop the engine. The safe transit of the load is the responsibility of the Install the articulation lock. Refer to Articulation transport contractor and driver.

  • Page 102: Articulation Lock

    Operation Transporting the Machine Articulation Lock Drive Position Transport Position WARNING Always make sure the articulation lock has been WARNING removed before attempting to drive the machine. The machine cannot be steered with the articulation lock Make sure the articulation lock is in the transport fitted.

  • Page 103: Lifting The Machine

    Operation Lifting the Machine Lifting the Machine Make sure that the lifting eye is directly above the WARNING centre of gravity of the machine. Communications Lift the machine. Make sure the lifting equipment Bad communications can cause accidents. Keep does not catch the machine. people around you informed of what you will be doing.

  • Page 104: Storage Of The Machine

    (in case the machine does not is in storage. start at the end of the storage period). Note: JCB Dealers must check stock monthly. Place suitable timbers under the machine to eliminate direct contact with the ground.

  • Page 105: Take The Machine Out Of Storage

    Operation Storage of the Machine Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. Prepare the machine for storage. Refer to Put the Machine into Storage. Take the Machine Out of Storage T2-079 Examine the coolant condition. Replace If necessary Examine all fluid levels.
  • Page 106 Operation Storage of the Machine Page left intentionally blank 9811-3400-4...

  • Page 107: Routine Maintenance

    JCB together with your Distributor wants you to be maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your...

  • Page 108: Fit For Purpose Tests For Lifting Equipment

    A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor.

  • Page 109: Health And Safety

    Hygiene vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin JCB lubricants are not a health risk when used properly for cancer. Do not handle used engine oil more than their intended purposes. necessary. Always use barrier cream or wear gloves to prevent skin contact.
  • Page 110 Routine Maintenance Health and Safety Avoid skin contact with oil soaked clothing. Don't keep oily rags in pockets. Wash dirty clothing before re-use. Throw away oil-soaked shoes. First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

  • Page 111: Battery

    Routine Maintenance Health and Safety Battery CAUTION T3-061 Damaged or spent batteries and any residue from fires WARNING or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance Batteries give off an explosive gas. Do not smoke with local environmental waste regulations.
  • Page 112 Routine Maintenance Health and Safety Warning Symbols First Aid - Electrolyte The following warning symbols may be found on the Do the following if electrolyte: battery. Gets into your eyes Symbol Meaning Immediately flush with water for 15 minutes, always get Keep away from children.

  • Page 113: Service Schedules

    Routine Maintenance Service Schedules Service Schedules Introduction How to Use the Service Schedules T3-036_3 T3-012_4 In the example shown, A shows all service requirements to WARNING be carried out every 10 hours and B shows the requirements to be carried out every 500 hours. Maintenance must be done only by suitably qualified and competent persons.

  • Page 114: Pre-Start Cold Checks, Service Points And Fluid Levels

    External Oil Leaks Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) In arduous conditions change the oil and filter after every 250 hours or three months (whichever comes first). (3) Clean more often when working in dusty operating environments (4) Change outer element more frequently in dusty operating environments.
  • Page 115   Driveshaft and Universal Joints Grease (1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Change the oil every 1500 hours. (3) Grease more frequently when operating in arduous conditions. Table 9. Hydraulics Operation...
  • Page 116  Battery Terminals for Condition and Tightness Check    Wiring for Chaffing and Routing Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. Table 11. Bodywork and Cab Operation 1000 2000  ...
  • Page 117        Foot Brake Operation Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. Table 13. Lifting Equipment Operation 1000 2000    Fit for Purpose Test Complete (1) First 100 Hours Service only, to be completed by your JCB Distributor.

  • Page 118: Functional Test And Final Inspection

     Air Inlet System Security Check    Coolant System for Leaks Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. Table 15. Transmission, Axles and Steering Operation 1000 2000    ...
  • Page 119        Proximity Sensor Function Check (1) First 100 Hours Service only, to be completed by your JCB Distributor. Table 18. Bodywork and Cab Operation 1000 2000  Glazing for Correct Fit Check  Doors and Hinges Check ...

  • Page 120: Fluids, Lubricants And Capacities

    (5) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. (6) If JCB Special MPL EP Grease is used for normal greasing, all 100 hour greasing operations must be carried out at ten (10) hour intervals.

  • Page 121: Coolant Mixtures

    The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F)

  • Page 122: Types Of Fuel

    Routine Maintenance Fluids, Lubricants and Capacities Types of Fuel CAUTION Consult your fuel supplier or JCB distributor about the Acceptable and Unacceptable Fuels suitability of any fuel you are unsure of. T3-048_2 Important: No warranty liability whatsoever will be GEN-9-2 accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.
  • Page 123 Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) then the fuel system must be filled with standard diesel (at 250 ppm.
  • Page 124 Routine Maintenance Fluids, Lubricants and Capacities Sulphur Content Effects of Fuel Contaminates T3-032 T3-033 High sulphur content can cause engine wear. (High The effect of dirt, water and other contaminants in diesel sulphur fuel is not normally found in North America, can be disastrous for injection equipment: Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.

  • Page 125: Tools

    Routine Maintenance Tools Tools Toolbox Keep the tools in the toolbox A unless you need to use them. To get access to the toolbox, open an engine cover. Refer to Access Panels, Engine Covers. We recommend that you lock the toolbox to prevent theft or tampering.

  • Page 126: Prepare The Machine For Maintenance

    Routine Maintenance Prepare the Machine for Maintenance Prepare the Machine for Maintenance Introduction WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key.

  • Page 127: How To Make The Machine Safe (Loader Arm Lowered)

    Routine Maintenance Prepare the Machine for Maintenance How to Make the Machine Safe (Loader How to Make the Machine Safe (Loader Arm Lowered) Arms Raised) P4-3016 If necessary, empty the shovel. WARNING Make sure that the machine is parked correctly in the Raised Equipment straight-ahead position on hard, level ground.

  • Page 128: Safety Mechanism

    Routine Maintenance Prepare the Machine for Maintenance Safety Mechanism Install the Maintenance Strut If necessary, empty the shovel. Make sure that the machine is parked correctly in the straight-ahead position on hard, level ground. Refer to Stopping and Parking the Machine (Operation Section).
  • Page 129 Routine Maintenance Prepare the Machine for Maintenance Stow the Maintenance Strut Make sure the park brake is engaged and the transmission is in neutral. Install the battery isolation key. Refer to Battery Isolator Switch. Start the engine. Lift the loader arm sufficiently to remove the weight from the maintenance strut A.

  • Page 130: Cleaning The Machine

    Routine Maintenance Cleaning the Machine Cleaning the Machine Introduction CAUTION T3-062_3 The engine or certain components could be damaged Clean the machine using water and or steam. Do not allow high pressure washing systems; special mud, debris etc. to build upon the machine. precautions must be taken if the engine is to be washed using a high pressure system.

  • Page 131: Cleaning The Machine

    Routine Maintenance Cleaning the Machine Cleaning the Machine WARNING To avoid burning wear personal protective equipment (PPE) when handling hot components. To protect your eyes, wear personal protective equipment (PPE) when using a brush to clean components. HYD-1-3_3 WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc.

  • Page 132: Checking For Damage

    Routine Maintenance Checking for Damage Checking for Damage Check the Machine Body and Structure Check the Tyres T3-063_5 T3-065_2 Make sure that all guards and protective devices are in WARNING place, attached by their locking devices and free from damage. You could be killed or injured if a machine tyre bursts.

  • Page 133: Checking The Rops/Fops Structure

    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 For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. 801230 Fig 66.

  • Page 134: Greasing

    Routine Maintenance Greasing Greasing Introduction Preparing the Machine for Greasing T3-028_2 You must grease the machine regularly to keep it working Make the machine safe before you start a greasing efficiently. Regular greasing will also lengthen the procedure. Refer Prepare Machine machine's working life.

  • Page 135: Loader Arms And Shovel

    Routine Maintenance Greasing Loader Arms and Shovel HT Machines 795510-1 Fig 67. Shovel and Link Pivot-Pins: Total of 10 grease points. (1 to 10). Loader Arm Pivot-Points: Total of 14 grease points (11 to 24) 9811-3400-4...
  • Page 136 Routine Maintenance Greasing ZX Machines 795520-1 Fig 68. Shovel and Link Pivot-Pins: Total of 4 grease points (1 to 4). Loader Arm Pivot-Points: Total of 9 grease points (5 to 13). 9811-3400-4...

  • Page 137: Centre Pivot, Rear Axle Pivots And Steer Rams

    Routine Maintenance Greasing Centre Pivot, Rear Axle Pivots and Steer Cab Door Hinges Rams S270310-1 Fig 70. When you grease the cab door hinges, open the door and stand as shown. 812220-1 Fig 69. Centre Pivot: Total of 3 grease points (1 to 3). Rear Axle Pivots: Total of 2 grease points (4 and 5).

  • Page 138: Driveshafts

    Routine Maintenance Greasing Driveshafts Total of 7 grease points S201770-1 Fig 71. 9811-3400-4...

  • Page 139: Automatic Greasing System (If Fitted)

    Routine Maintenance Greasing Automatic Greasing System (if fitted) P4-3004 Introduction The following points are greased by the automatic greasing system (when fitted): – Shovel Pivot Pins – Loader Arm Pivot Points – Centre Pivot and Steering Rams Note: All other grease points must continue to be greased as per the Service Schedules When the ignition is ON, the greasing system performs all TWIN...
  • Page 140 Routine Maintenance Greasing Filling the Reservoir It is essential that the correct grease is used in this system. Refer to Fluid, Lubricants and Capacities. Remove the dust cap from the filler coupling A. Carefully clean the area around the filler coupling and the coupling on the filler hose.
  • Page 141 Routine Maintenance Greasing Testing the System In order to test the correct operation of the system, carry out a single greasing cycle. Turn starter switch to IGN. Press test button D for 3 to 5 seconds. The system will perform a single cycle test. In order to prime the system after cleaning the machine or to vent the system;...
  • Page 142 Routine Maintenance Greasing Replacing the Fill Point Filter Clean the area around the filler coupling E. Remove the filler coupling E from the filter G. Loosen locknut F. Remove filter G. Note: Grease may flow from the housing when the filter is removed.

  • Page 143: Access Panels

    Routine Maintenance Access Panels Access Panels Rear Grille Heater Door P4-3006 Opening and Closing Opening and Closing To open the rear grille: To open the heater door: Make the machine safe with the loader arms lowered. Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.

  • Page 144: Engine Covers

    Routine Maintenance Access Panels Engine Covers Opening and Closing WARNING The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open. 5-2-6-5 WARNING Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running.

  • Page 145: Heater And Air Conditioning

    Routine Maintenance Heater and Air Conditioning Heater and Air Conditioning Cleaning the Air Intake Filter P4-3008 CAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6 Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.

  • Page 146: Cleaning The Re-Circulation Filter (If Fitted)

    Routine Maintenance Heater and Air Conditioning Cleaning the Re-Circulation Filter (if fitted) P4-3019 CAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6 Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.

  • Page 147: Adjusting The Compressor Belt

    Routine Maintenance Heater and Air Conditioning Adjusting the Compressor Belt WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 Note: The engine shown is the type installed to the early machines. The engines on later machines can look different but the procedure does not change.

  • Page 148: Brakes

    Use the UP and DOWN arrows to select the park If you have any queries concerning the park brake test or brake test menu. adjustment procedures, consult your local JCB distributor. c Press SETUP key to select park brake test on. Testing the Park Brake...
  • Page 149 Park Brake Disconnect 0011 This adjustment is only for the 426 and 436 machines. The When fully engaged the park brake electrically disconnects 456 has a push button park brake, this adjustment must be the transmission drive, this prevents the machine from done by a service engineer.

  • Page 150: Service Brake

    Routine Maintenance Brakes Service Brake Testing the Service Brake P4-2006_2 CAUTION Do not use a machine with faulty brakes. 0093 The service brakes on this machine are backed up by accumulators. In the event of accumulator failure, the foot brakes would be inoperative with the engine stopped. It is essential that the operation of the accumulators is checked regularly, using the following procedure: Park the machine on firm level ground, lower the...

  • Page 151: Electrical System

    Routine Maintenance Electrical System Electrical System Battery Checking the Electrolyte Level T3-020_3 Low maintenance batteries used in normal temperate Battery Disconnection/Connection climate applications should not need topping up. However, T3-019_4 in certain conditions (such as prolonged operation at WARNING tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.

  • Page 152: Battery Isolator Switch

    Routine Maintenance Electrical System Battery Isolator Switch To disconnect the battery from the machine electrics a battery isolator has been fitted. CAUTION Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is fitted.

  • Page 153: Jump Starting The Engine

    If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply.

  • Page 154: Fuses

    Routine Maintenance Electrical System Fuses Primary Fuses The primary fuses A are located in two fuse boxes, which Introduction are mounted at the right side of the battery bay inside the rear grille. CAUTION If a fuse breaks, find the cause and correct the fault before Fuses a new fuse is installed.
  • Page 155 Routine Maintenance Electrical System Fuse Circuit(s) Protected Rating Front Work Lights Ignition 1 EMS (Ignition Feed) ZF Computer (Ignition Feed) ACCS Reversing Camera Emergency Steer System ESOS and Immobiliser Reverse Alarm and Lights Blank Hazard Indicators Beacon and Interior Light Radio (24V) T034230-1 Fig 90.
  • Page 156 Routine Maintenance Electrical System Secondary Fuses Fuse Circuit(s) Protected Rating Reversing Camera All the fuses are shown (including optional equipment Emergency Steer System fuses). Your machine may not be equipped with all the fuses shown. Shutdown Relay, Immobiliser Reverse Alarm and Lights Fuse Circuit(s) Protected Rating 24/12V Dropper (Radio, Cigar /Lighter,...

  • Page 157: Relays

    Routine Maintenance Electrical System Relays Relay Circuit Ignition 1 The relays A are located in a fuse box (shown with the Ignition 2 cover removed) behind the operators seat. They are separated into banks. Each relay position in each bank is Brake Lights numbered.

  • Page 158: Engine

    Machine for Maintenance. Note: Wait at least 15 minutes after the engine is stopped 866840-1 Fig 94. 426, 436 before you check the oil level. This gives time for the oil to drain into the oil pan. Open the engine cover. Refer to Access Panels, Engine Cover.
  • Page 159 Routine Maintenance Engine Changing the Oil and Filter CAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. 13-3-1-15 Drain the oil when the engine is warm to: –...

  • Page 160: Cooling System

    Routine Maintenance Engine Cooling System WARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 9-3-3-1_2 Checking the Coolant Level Make the machine safe with the loader arms lowered.
  • Page 161 Routine Maintenance Engine Changing the Coolant Do not overfill. Fit the filler cap. Note: A 50% antifreeze mixture must be used even if frost Make the machine safe with the loader arms lowered. protection is not needed. This gives protection against Refer to Prepare the Machine for Maintenance.
  • Page 162 Routine Maintenance Engine Changing the Coolant Filter (456) Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance. WARNING The cooling system is pressurised when the coolant is A262870-1 hot. When you remove the cap, hot coolant can spray Fig 100.

  • Page 163: Drive Belt

    The maximum movement at the longest run of the drive belt D must be 9.5 to 12.7 mm (0.375 to 0.5 in). 862020-1 If there is too much movement, get your JCB Dealer Fig 103. 426, 436 to replace the drive belt.

  • Page 164: Air Filter

    Routine Maintenance Engine Air Filter Changing the Elements Cleaning the Air Filter Dust Valve CAUTION T3-034 The outer element must be renewed immediately if the Important: Do not run the engine with the dust valve K warning light on the instrument panel illuminates. removed.
  • Page 165 Routine Maintenance Engine Refit cover B making sure it is properly located then Connect the induction hose J. Make sure the air filter secure latches A. Make sure that the dust valve K is blocked switch connector is fitted. Check all hoses for at the bottom.

  • Page 166: Fuel System

    Close and lock the engine cover. CAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 2-3-3-11 862310-2 Fig 108. 426, 436 823800-1 Fig 107. 456 9811-3400-4...
  • Page 167 To assist with bleeding, fill the filter element with fuel before fitting. Install filter element, hand tight only. Check for leaks. Bleed fuel system. K Bleeding System ( T 157). Close and lock the engine cover. 862310-1 Fig 109. 426, 436 823800-4 Fig 110. 456 9811-3400-4...

  • Page 168: Sedimentor Bowl

    Routine Maintenance Fuel System Sedimentor Bowl Cleaning the Sedimentor Bowl If bowl B contains sediment carry out the following: Draining the Sedimentor Bowl Hold the bowl B and unscrew domed nut C. Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance.

  • Page 169: Bleeding The System

    Routine Maintenance Fuel System Bleeding the System Bleed the injectors a Slacken one of the injector feed pipe nuts C. CAUTION b Crank the engine, when air free fuel flows from the Running the engine with air in the system could connection, tighten the nut.
  • Page 170 Routine Maintenance Fuel System S269700-1 Fig 113. 9811-3400-4...

  • Page 171: Hydraulic System

    Routine Maintenance Hydraulic System Hydraulic System Introduction CAUTION Do not allow dirt to enter the system. Before WARNING disconnecting any part of the system, thoroughly clean around the connection. When a component has The temperature of the hydraulic oil will be high soon been disconnected, always fit protective caps and after stopping the engine.

  • Page 172: Oil And Filter

    Refer to Prepare the Machine for Maintenance. CAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4 The level should be visible in the sight glass A.
  • Page 173 Refer to Prepare the Machine for Maintenance. CAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4 The level should be visible in the sight glass A.
  • Page 174 Routine Maintenance Hydraulic System Hydraulic Tank Filler Cap (456) The hydraulic tank breather (and filter) forms an integral part of the hydraulic tank cap B. Replace the cap (and breather filter) with a new one at the recommended interval. The cap incorporates a side mounted barrel lock that is operated by the ignition/door key.
  • Page 175 Changing the Filter Element Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance. 426, 436: Open the right side engine cover. 456: Open the right hand side top step. Remove hydraulic tank cap.

  • Page 176: Transmission

    Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance. Do not stop the engine. 426, 436: Open the left side engine cover. 812160-1 Fig 120. 426, 436 456: Open the right side top step.
  • Page 177 Routine Maintenance Transmission Changing the Oil and Filter WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.

  • Page 178: Front And Rear Axles

    Routine Maintenance Transmission Front and Rear Axles Checking the Oil Level CAUTION The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given. 16-3-5-3 CAUTION It is not recommended that the machine be driven with the axle partially filled with oil.
  • Page 179 Routine Maintenance Transmission Changing the Oil Make the machine safe with the loader arm lowere. Refer to Prepare the Machine for Maintenance. Clean the area around the fill/level plug A. Remove the fill/level plug A and its seal. Put a suitable container below the drain plug B (to catch the oil).
  • Page 180 Routine Maintenance Transmission Checking the Hub Oil Level P4-3014 Note: You must do the hubs separately. Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance. Make sure the OIL LEVEL mark on the hub is in the horizontal position, as shown.
  • Page 181 Routine Maintenance Transmission Changing the Hub Oil Note: You must do the hubs separately. Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance. Make sure the fill/drain plug A is at the bottom, as shown.

  • Page 182: Zf Axles

    Clean, then install the dipstick and screw plug 1 Replace the O-ring, if necessary. Introduction Tighten the screw plug to 50 Nm. The 426 has MT-L 3075 II - front axles and MT-L 3065 II - Changing the Oil rear axles. Stop the machine on hard, level ground.
  • Page 183 Routine Maintenance Transmission 333-T3830-1-1 Fig 128. 3065/3075 Dipstick and screw plug Drain plug Drain plug Breather 9811-3400-4...
  • Page 184 Routine Maintenance Transmission 3085 Axles Clean the area around the oil fill and check plug 3, drain plugs 1 and 2 and the breather 4. Checking the Oil Level Remove the oil fill and check plug 3. CAUTION Put a suitable container below the drain plugs (to catch the oil).
  • Page 185 Routine Maintenance Transmission 333-T3829-1-1 Fig 129. 3085 Drain plug Drain plug Oil fill and check plug Breather 9811-3400-4...
  • Page 186 Routine Maintenance Transmission 3095 Axles Clean the area around the oil fill and check plug 3, drain plugs 1 and 2 and the breather 4. Checking the Oil Level Remove the oil fill and check plug 3. CAUTION Put a suitable container below the drain plugs (to catch the oil).
  • Page 187 Routine Maintenance Transmission 333-T66239-1-1 Fig 130. 3095 Drain plug Front axle Drain plug Rear axle Oil fill and check plug View point Breather View point 9811-3400-4...

  • Page 188: Tyres And Wheels

    Routine Maintenance Tyres and Wheels Tyres and Wheels Tyre Inflation in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job. Introduction T3-066 Prepare the wheel. WARNING Before you add air to the tyre, make sure it is correctly An exploding tyre can kill.

  • Page 189: Checking The Wheel Nut Torques

    Routine Maintenance Tyres and Wheels Checking the Wheel Nut Torques WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8 On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours...

  • Page 190: Windscreen Washers

    Routine Maintenance Windscreen Washers Windscreen Washers Make the machine safe with the loader arm lowered. Refer to Prepare the Machine for Maintenance. To gain access to the washer bottle A, open the heater compartment door. Refer to Access Panels - Heater Door.

  • Page 191: Fire Extinguisher (If Fitted)

    Routine Maintenance Fire Extinguisher (if fitted) Fire Extinguisher (if fitted) T3-022 Checking the Fire Extinguisher Check the fire extinguisher for damage, security and signs of leaking. Check that the gauge A indicates that the extinguisher is charged i.e. the needle is in the GREEN segment. Note: If the needle is in or very near the RED segment at either end of the gauge, the extinguisher must be serviced or replaced.
  • Page 192 Routine Maintenance Fire Extinguisher (if fitted) Page left intentionally blank 9811-3400-4...

  • Page 193: Optional Attachments

    JCB cannot be held responsible. In addition the The use of non-approved attachments could invalidate machine's warranty and any other legislative compliance your warranty. may be affected by the use of non JCB approved 2-4-5-2_1 attachments. CAUTION If your machine needs the hydraulic system adapting to...

  • Page 194: Attachments For Your Machine

    Install attachments only on the machines for which they were designed. 5-5-1-1_2 An attachment helps to increase the productivity of your machine, for more information contact your JCB Dealer. These attachments are designed to be used with the Quickhitch: – Standard Shovel –...

  • Page 195: Connecting/Disconnecting Hydraulic Hoses

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses T4-004_2 Introduction Connecting the Hydraulic Hoses Make machine safe. Refer Routine WARNING Maintenance, Prepare Machine Maintenance. Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the Vent the hydraulic system. Refer to Routine skin.

  • Page 196: Disconnecting The Hydraulic Hoses

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Disconnecting the Hydraulic Hoses Make machine safe. Refer Routine Maintenance, Prepare Machine Maintenance. Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure. T037420 Fig 135. Disconnect the hoses. To allow for length changes when the hose is If the hoses have quick releases couplings, then refer pressurised, do not clamp at the bend.

  • Page 197: Quick Release Couplings

    Optional Attachments Connecting/Disconnecting Hydraulic Hoses Quick Release Couplings by dirt in the coupling or physical damage due to abuse. – Connect and disconnect new couplings two or three WARNING times to work the PTFE seals. Sometimes a new coupling will stick if the seal has not been worked. The external surfaces of the couplings must be clean before connecting or disconnecting.
  • Page 198 Optional Attachments Connecting/Disconnecting Hydraulic Hoses Connecting Quick Release Couplings Remove any residual hydraulic pressure trapped in the service line hose. Wipe the two faces of the male and female couplings and make sure they are clean. Make sure that ball C in the female coupling is located in one of its slots.

  • Page 199: Quickhitch Control

    Optional Attachments Quickhitch Control Quickhitch Control Introduction WARNING If two people are doing this job make sure that the person working the controls is a competent operator. If the wrong control lever is moved, or if the controls are moved violently, the other person could be killed or injured.

  • Page 200: Disengage The Attachments

    Optional Attachments Quickhitch Control Disengage the Attachments In this procedure to disengage the attachment, the Quickhitch isolator switch is used to divert the hydraulic power. If your machine has a power diverter lever substitute this in the procedure for the Quickhitch Isolator Switch.
  • Page 201 Optional Attachments Quickhitch Control T012740-1 Fig 142. Multi-controls lever 801590-2 Fig 143. 9811-3400-4...

  • Page 202: Engage The Attachments

    Optional Attachments Quickhitch Control Engage the Attachments In this procedure to engage the attachment, the Quickhitch isolator switch is used to divert the hydraulic power. If your machine has a power diverter lever substitute this in the procedure for the Quickhitch Isolator Switch. Align the machine square with the attachment.
  • Page 203 Optional Attachments Quickhitch Control T012740-2 Fig 147. Multi-controls lever 801590-1 Fig 148. 9811-3400-4...

  • Page 204: Work Platforms

    In the case of uncertainty, guidance should be sought from the relevant local or government authority. JCB supply integrated work platforms solely for use in Europe which comply with the requirements of European Directive 2006/42/EC. Contact your dealer for further details.

  • Page 205: Specifications

    Specifications Static Dimensions Turning Circles T034500 Fig 149. Note: Your machine may look different from the model shown. Machine Tyre Shovel R1 (Outer Shovel R2 (Outer Tyre R3 (Inner Tyre Radius) Radius) Radius) mm (ft-in) mm (ft-in) mm (ft-in) 20.5R25 XHA L3 5985 (19-7) 5422 (17-9) 2825 (9-3)
  • Page 206 Specifications Static Dimensions 811980 Fig 150. 9811-3400-4...
  • Page 207 Specifications Static Dimensions Table 25. mm (ft-in) mm (ft-in) Overall length (includes standard shovel) 6831 (22-5) 6831 (22-5) Axle to pivot pin 1096 (3-7) 1096 (3-7) Wheelbase 3000 (9-10) 3000 (9-10) Axle to counterweight face 1816 (5-11) 1816 (5-11) Minimum ground clearance 442 (1-5) 442 (1-5) Height over exhaust...
  • Page 208 Specifications Static Dimensions 811980 Fig 151. 9811-3400-4...
  • Page 209 Specifications Static Dimensions Table 26. mm (ft-in) mm (ft-in) Overall length (includes standard shovel) 6926 (22-9) 7169 (23-6) Axle to pivot pin 1143 (3-9) 1143 (3-9) Wheelbase 3000 (9-10) 3000 (9-10) Axle to counterweight face 1816 (5-11) 1816 (5-11) Minimum ground clearance 459 (1-6) 459 (1-6) Height over exhaust...
  • Page 210 Specifications Static Dimensions 795100 Fig 152. 9811-3400-4...
  • Page 211 Specifications Static Dimensions Table 27. mm (ft-in) mm (ft-in) Overall length (includes standard shovel) 8520 (27-11) 8520 (27-11) Axle to pivot pin 1713 (5-7) 2182 (7-2) Wheelbase 3300 (10-10) 3300 (10-10) Axle to counterweight face 1970 (6-5) 1988 (6-6) Minimum ground clearance 470 (1-6) 470 (1-6) Height over exhaust...

  • Page 212: Working Capacity

    Specifications Working Capacity Working Capacity Introduction All rated capacities are based on the criteria of the machine being level and on a firm supporting ground. When the machine is operated in conditions that deviate from these criteria (for example on soft or uneven ground, on a slope or when subject to side loads), these conditions shall be taken into account by the operator.
  • Page 213 Specifications Working Capacity Table 28. General Purpose Shovel (with Reversible Toe-Plate) Direct Mount Quickhitch Mount Shovel Shovel Full Turn Tip Payload Shovel Full Turn Tip Payload Size Weight Load Weight Load kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Model 810 (1785)
  • Page 214 Specifications Working Capacity Table 31. General Purpose Shovel (with Reversible Toe-Plate) Direct Mount Quickhitch Mount Shovel Shovel Full Turn Tip Payload Shovel Full Turn Tip Payload Size Weight Load Weight Load kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Model 1163 (2563)
  • Page 215 Specifications Working Capacity Table 34. Shovel Type Shovel Size Shovel Weight Full Turn Tip Load Cubic Metre kg (lb) kg (lb) General purpose 1644 (3624) 11600 (25573) General purpose 1717 (3785) 11527 (25412) General purpose 1760 (3880) 11484 (25318) Penetration (with tipped teeth) 1652 (3642) 11592 (25556) 9811-3400-4...

  • Page 216: Maximum Travel Speeds

    Specifications Maximum Travel Speeds Maximum Travel Speeds Machines with ZF Axles Forward Reverse kph (mph) kph (mph) Forward Reverse 1st gear 7.4 (4.6) 7.4 (4.6) kph (mph) kph (mph) 2nd gear 14.5 (9.0) 14.5 (9.0) 1st gear 7.7 (4.8) 7.9 (4.9) 3rd gear 25.2 (15.6) 25.2 (15.6)

  • Page 217: Tyre Sizes And Pressures

    – An average loading cycle speed of 6mph (10kph). Note: If the tyres fitted to your machine are not shown, then contact your JCB Dealer for advice, Do not guess the Refer to the tyre manufacturer for: tyre pressures.

  • Page 218: Noise Data

    The noise data values shown only apply to CE marked machines. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Definition of terms: A-weighted sound pressure level measured at the operator's station.

  • Page 219: Vibration Data

    Specifications Vibration Data Vibration Data Introduction Minimising Exposure to Vibration T5-001 Exposure to vibration can be minimised through: To assist in compliance with European Directive 2002/44/ EC, duty specific vibration emission values for this – Selection of the correct size and capacity of machine, machine type have been provided on the following page(s) equipment attachments...
  • Page 220 Specifications Vibration Data 426, 436 Table 36. Whole-Body Vibration Emission Under Representative Operating Conditions (According to the intended use) Dominant Axis (X, Y or Z) 810560-1 Machine Operating Duties Whole-body vibration emission determined in accordance Machine Operating Duties with ISO 2631 - 1: 1997 for this machine type is 0.4 m/s normalised to an 8 hour reference period [A(8)] and based upon a test cycle "defined in SAE J1166".
  • Page 221 Specifications Vibration Data Table 37. Whole-Body Vibration Emission Under Representative Operating Conditions (According to the intended use) Dominant Axis (X, Y or Z) 0.55 0.37 0.32 0.17 0.03 T001260 Machine Operating Duties Whole-body vibration emission determined in accordance with ISO 2631 - 1: 1997 for this machine type is 0.32 m/s normalised to an 8 hour reference period [A(8)] and based upon a test cycle "defined in SAE J1166".
  • Page 222 Specifications Vibration Data Page left intentionally blank 9811-3400-4...

  • Page 223: Warranty Information Machine Service Record Sheet

    Warranty Information Machine Service Record Sheet Warranty Information Machine Service Record Sheet T6-005 Installation Checklist 3000 Hrs./18 Month Date: Date: Hour reading: 1st 100 Hrs./2 Weeks 3500 Hrs./21 Month Date: Date: Hour reading: Hour reading: 500 Hrs./3 Month 4000 Hrs./24 Month Annual insurance Date: Date:...
  • Page 224 Warranty Information Machine Service Record Sheet 6500 Hrs./39 Month 9500 Hrs./57 Month Date: Date: Hour reading: Hour reading: 7000 Hrs./42 Month 10000 Hrs./60 Month Annual insurance Date: Date: Hour reading: Hour reading: 7500 Hrs./45 Month Date: Hour reading: 8000 Hrs./48 Month Annual insurance Date: Hour reading:...

  • Page 225: Registration Information

    Installing Engineer Installing Engineer Customer's Name Dealer Copy (U.K. and Eire only) - Do not send back to JCB Service. A copy of the registration details to be Address sent direct to: The Equipment Register Ltd. (T.E.R.) Bath and West Buildings P.D.I.
  • Page 226 Warranty Information Registration Information Page left intentionally blank 9811-3400-4...

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