JCB Idle Control Update

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CONTENTS
Bulletin Index
420,425,426,435,436 & 456 4/000

The index will be updated at periodic intervals
T. I. No. Machine F.S.I. Subject Date
6/015 420,425 & 430 JCB CD90 Axle Crownwheel Bolts Apr. '95
6/016 426/436 Parking Brake Warning Nov. ‘95
6/017 426 Idle Control Dec. ‘95
6/018 436 Idle Control Dec. ‘95
6/019 426/436 Air Conditioning Compressor Mounting Bolt Apr. ‘96
6/020 436 S471 P.T.O. Shaft Replacement Sep. ‘96
6/021 436 Hydraulic Pressures Feb. ‘97
6/022 B83/N. Am. 426/436 Rear Grille/Bodywork Support Feb. ‘97
6/023 426/436 S621/622 Engine Oil Cooler Hoses May ‘97
6/024 E148/N. Am. 426/436 Main Feed Pipe Jun. ‘97
6/025 456B S634 Servo Control Update Jul. ‘97
6/026 E149/N. Am. 426/436/456 Hydraulic Filter Head Jul. ‘97
6/027 456 S637 Engine Coolant Expansion Tank Nov. ‘97
6/028 E157/N. Am. 436 S658 Priority Pipe Nov. ‘97
6/029 E156/N. Am. 426 Priority Pipe Nov. ‘97
6/029 E156/N. Am. 426 Priority Pipe Issue 2 Feb. ‘98
WITH EFFECT FROM DECEMBER 1997, ALL WHEELED LOADER BULLETINS WILL HAVE THE PREFIX 4, IE. PREFIX 6 WILL
NO LONGER BE USED.
TECHNICAL INDEX
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INFORMATION
! SAFETY NOTICE - Instructions in the Service Bulletins assume that the Number 6/015
engineer has a sound knowledge of safety procedures and has been trained in the
maintenance and repair of JCB equipment. If you are unsure or do not understand Issue 1
information contained in the Service Bulletins then ask your supervisor or contact Date Apr. 1995
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST.
SUBJECT: JCB CD90 Crownwheel Bolts Page 1 of 1
MACHINES AFFECTED: 420, 425 and 430 Machines fitted with CD90 Axles
TO BE CARRIED OUT: For Information Only
SERVICE INFORMATION:
To commonise service parts required, the 8.8 grade retaining bolts and locktabs may be replaced by Verbus Ripp
12.9 Grade Bolts, during an axle repair or overhaul.
The 12.9 grade bolts provide increased durability due to the increase clamping from higher tightening torque.
SERVICE PROCEDURE:
1 Fit the crownwheel to the differential assembly as per

the relevant Service Manual.
DO NOT FIT dowels B and locktabs C.
2 Fit 12.9 grade crownwheel bolts A, torque tighten

each bolt in turn to 166 Nm (125 lbf ft).
Note: Use only new Verbus Ripp bolts.
Parts Required
Item Part Number Description Qty

A 826/01080 M12 x 30 Verbus Ripp Bolt 12
B
C
A
THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
ISSUED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE, ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND
TECHNICAL INDEX
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INFORMATION
information contained in the Service Bulletins then ask your supervisor or contact
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Oct. 1995
Page 1 of 2
SUBJECT: Master warning light and buzzer inoperative when parking brake warning
operates.
MACHINES AFFECTED: 426 Machines up to Serial Number 531051

436 Machines up to Serial Number 533056
TO BE CARRIED OUT: In the event of customer complaint that machine does not match Handbook.
SERVICE PROCEDURE:
1 Park the machine on firm level ground. Stop the engine and engage the parking brake.
2 Isolate the machine electrics.
3 Remove the insrument panel from the moulding.
4 Disconnect the side console harness 10 way plug (SH) and 14 way plug (SJ).
Note: The white terminal retainers must be removed before inserting or removing terminals. Refit retainer after
insertion/removal.
5 Remove wire 420 (Terminal 5) from the 10 way plug (SH) and insert into spare position next to wire 420C of
adaptor harness A. Insert wire 420C into terminal 5 of 10 way plug (SH).
6 Remove wire 421 (Terminal 11) from the 14 way plug (SJ) and insert into spare position next to wire 421C of
adaptor harness B. Insert wire 421C into terminal 11 of 14 way plug (SJ).
7 Plug diode B into the 2 way plug on adaptor harness A.
Test Procedure
With the parking brake engaged, if forward or reverse drive is selected, the instrument panel warning light and the
master warning light will illuminate and the warning buzzer will sound.
Page 2 of 2 T.I. 6/016 Issue 1
Parts Required
Item Part No. Description Qty.
A 721/00034 Adaptor Harness 1

B 716/10700 Diode 1
Warranty Information
Warranty time allowed - 0.5 Hours
B
TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Dec. 1995
SUBJECT: Idle Control Page 1 of 4
MACHINES AFFECTED: JCB 426 HT and ZX machines up to Ser. No. 531055 plus 531058, 531059 & 531060
TO BE CARRIED OUT: In the event of customer complaint for machines as listed above.
Machine may stall when hydraulic services are used at engine tickover.
SERVICE PROCEDURE:
1 Park the machine on firm level ground. Stop the engine and engage the parking brake. Fit the articulation lock.
2 Operate the loader controls to exhaust hydraulic pressure in the system and release the hydraulic filler cap.
3 Sub-assemble solenoid valve 9 with adaptors 18, hoses 11 (leave hoses loose) and mounting plate 10, fit using
items 14, 15 and 16.
4 Remove and discard emergency steer valve mounting bolts, position solenoid sub-assembly on top and secure
using bolts 17.
5 Disconnect hose Z from front of left hand shuttle valve, fit tee adaptor 13, refit hose and fit hose 11, (phase hoses
for best run).
6 Loose fit hose 11 to tee adaptor 12.
7 Disconnect hose A (existing) from tank sideplate and connect to tee adaptor 12. Connect tee adaptor 12 to tank
sideplate (phase hoses for best run).
Note: Fluid will be lost during this operation.
8 Tighten all hoses.
9 Remove existing throttle switch bracket and throttle switch (if fitted), fit new bracket 6. Refit throttle switch (if
fitted) and fit new switch 5.
10 Install harness as per Fig. 2.
TECHNICAL DATA
Idle Control Pressure 170 ± 5 bar

Engine Speed to cut-off Idle Control Valve 950-1000 rpm.
Note: Above 950 - 1000 rpm system pressure is controlled by the pump control valve.
Equipment Required
Pressure gauge 0-400 bar

Tachometer
Pressure Setting Procedure
Fit pressure gauge to measure pump pressure (at emergency steer valve X (See fig. 1)).
Set idle speed as stated.
Adjust idle control proximity switch
1 Working underneath cab (engine off)pull throttle lever

towards proximity switch.
2 Adjust proximity switch end gap so that the linkage Fig. 1

JUST passes (clearance is critical).
3 Roughly set proximity switch so that throttle lever leads Y

by approximately 5 mm. X
4 Start engine, operate arms lower.
5 Adjust idle control valve Y (See fig. 2) as specified

(1 turn = 30 bar).
6 Slowly depress throttle pedal and note engine speed

when pressure rises to full system pressure.
7 Adjust proximity switch to achieve specified cut off

engine speed.
8 Tighten proximity switch then recheck engine speed.
Check Machine Operation
Check engine does not stall with full electrical Load and transmission selected, by operating Quickhitch locking
pins or by crowding bucket fully back. If engine stalls, increase idle or decrease regulated pressure within limits.
Parts Required - (Order Kit Part No. 993/88700)

2 721/00008 Idle Control Harness 1
3 716/11100 Relay 1
4 7201/0009 Fuse Board Terminal 1
5 701/42100 Proximity Switch 1
6 265/01189 Throttle Switch Bracket 1
7 1315/0205Z Bolt 2
8 1370/0103Z Nut 2
9 25/990000 Solenoid Relief Valve 1
10 265/01204 Mounting Plate 1
11 611/21300 Hose 2
12 816/50010 Tee Adaptor 1
13 816/50031 Tee Adaptor 1
14 1315/3212Z Bolt 2
15 1420/0006Z Washer 2
16 1425/0006Z Spring Washer 2
17 1315/3314Z Bolt 2
18 1620/0001 Adaptor 2
RE 1
RF 2
3
4
RA
RG
101D
RB
RD
Fig. 2
Harness Connection
1 Connect connector RA to solenoid valve. 5 Remove wire 101H and its terminal from the fuse
board (Fuse 4A). Crimp wire 101H and wire 101D
2 Connect terminal RB onto solenoid valve mounting (on idle control harness) into new terminal provided.
bracket. Insert this terminal into fuse board in the same
position.
3 Connect connector RD to new proximity switch.
Note: Connector RE is used on 436 ONLY
4 Fit relay base RF to other bases in the fuse box .
Note: The idle control harness is to be routed out of the cab through the servo loom cover.

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TECHNICAL INDEX
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INFORMATION
information contained in the Service Bulletins then ask your supervisor or contact Date Dec. 1995
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST.
SUBJECT: Idle Control Page 1 of 4
MACHINES AFFECTED: JCB 436 HT and ZX machines up to Ser. No. 533060

Except 533040, 533046 & 533057
TO BE CARRIED OUT: In the event of customer complaint for machines as listed above.
Machine may stall when hydraulic services are used at engine tickover.
SERVICE PROCEDURE:
1 Park the machine on firm level ground. Stop the engine and engage the parking brake.
2 Operate the loader controls to exhaust hydraulic pressure in the system and release the hydraulic filler cap.
3 Sub-assemble solenoid valve 9 with adaptors 18 and restrictor adaptor 19, hoses 11&12 (leave hoses loose) and
mounting plate 10, fit using items 14, 15 and 16.
4 Remove and discard emergency steer valve mounting bolts, position solenoid sub-assembly on top and secure
using bolts 17.
5 Remove pressure test adaptor from top of secondary pump.
6 Remove Hose at bottom of secondary pump (Pump to shuttle valve). Remove adaptor at bottom of small pump
and refit at top.
7 Fit pressure test adaptor at bottom of secondary pump.
8 Connect hose 12 to top of secondary pump.
9 Connect hose 11 to top of shuttle valve.
10 Loose fit hose 11 to tee adaptor 13.
11 Disconnect hose A (existing) from tank sideplate and connect to tee adaptor 13. Connect tee adaptor 13 to tank
sideplate (phase hoses for best run).
Note: some fluid will be lost during this operation.
12. Tighten all hoses.
13 Remove existing throttle switch bracket and throttle switch (if fitted), fit new bracket 6. Refit throttle switch (if
fitted) and fit new switch 5.
14 Install harness as per Fig. 2.
TECHNICAL DATA
Engine speed to cut-in secondary pump 1150 - 1250 rpm.

Set secondary pump to 250 bar.
OPERATION
At Low RPM Solenoid valve operates via throttle proximity switch and disables the secondary pump.
At High RPM Solenoid valve de-energises and full pressure is available. Pump can be selectively dumped by
pressing and holding the forward button on the loader lever.
Equipment Required
Pressure gauge 0-400 bar

Tachometer
Pressure Setting Procedure
Fit pressure gauge to measure pump pressure (at secondary pump flange X (See fig. 1)).
Fit tachometer.
Set Steering to left hand lock
Set idle speed as specified in Service Manual.
Adjust idle control proximity switch
1 Working underneath cab (engine off)pull throttle lever Fig. 1

towards proximity switch.
2 Adjust proximity switch end gap so that the linkage

JUST passes (clearance is critical).
3 Roughly set proximity switch mid-way in slot but do not

fully tighten.
4 Start engine, operate arms lower.
5 Slowly depress throttle pedal and note engine speed

when secondary pump rises to full system pressure.
X
6 Adjust proximity switch to achieve specified cut-in
engine speed.
7 Tighten proximity switch then recheck engine speed.
Check ‘Boost’ Operation
Dead-head a service and check secondary pressure according to table:
‘BOOST’ BUTTON
ENGINE SPEED BUTTON NOT USED PRESS & HOLD RELEASE BUTTON
Idle Standby Standby Standby
Above valve cut-in rpm Full pressure Standby Full pressure
Parts Required - (Order Kit Part No. 993/88800)

2 721/00008 Idle Control Harness 1
3 716/11100 Relay 1
4 7201/0009 Fuse Board Terminal 1
5 701/42100 Proximity Switch 1
6 265/01189 Throttle Switch Bracket 1
7 1315/0205Z Bolt 2
8 1370/0103Z Nut 2
9 25/989900 Solenoid Valve 1
10 265/01204 Mounting Plate 1
11 611/21300 Hose 2
12 611/27500 Hose 1
13 816/50010 Tee Adaptor 1
14 1315/0210Z Bolt 2
15 1420/0006Z Washer 2
16 1425/0006Z Spring Washer 2
17 1315/3314Z Bolt 2
18 1620/0001 Adaptor 2
19 816/15064 Restrictor Adaptor 1
RE 1
RF 2
3
4
RA
RG
101D
RB
RD
Fig. 2
Harness Connection
1 Connect connector RA to solenoid valve. 5 Disconnect the connector on transmission dump

button from side console harness (identified by wires
2 Connect terminal RB onto solenoid valve mounting 101M and 9600A), connect this to connector RE on
bracket. idle control harnmess.
3 Connect connector RD to new proximity switch. 6 Remove wire 101H and its terminal from the fuse
board (Fuse 4A). Crimp wire 101H and wire 101D
4 Fit relay base RF to other bases in the fuse box . (on idle control harness) into new terminal provided.
Insert this terminal into fuse board in the same
position.
Note: The idle control harness is to be routed out of the cab through the servo loom cover.

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TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Apr. 1996
SUBJECT: Air Conditioning Compressor Mounting Bolt
MACHINES AFFECTED: Machines fitted with air conditioning prior to cut-in numbers:
426: 531072
436: 533083
TO BE CARRIED OUT: In the event of failure of the mounting bolt
Situations have arisen of the compressor mounting bolt breaking.
SERVICE PROCEDURE:
1 Slacken adjuster bolt A.
2 Remove bolt B and replace with capscrew C.
3 Adjust compressor to give correct belt tension and

retighten all bolts.
B
Parts Required C
C 1391/3423Z Cap Screw 1
SPECIAL INSTRUCTIONS
Warranty Ref. No. - S462
Warranty time allowed - 0.5 Hour Closing Date - 01/04/97
TECHNICAL INDEX
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INFORMATION
9/008
engineer has a sound knowledge of safety procedures and has been trained in the (B?/N. Am.)
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Sept.
Mon. 1996
1995
SUBJECT: 436 P.T.O. Shaft
MACHINES AFFECTED: 436HT and 436 ZX - Serial Nos. 533001 to 533123 except 533121
TO BE CARRIED OUT: Immediately
Due to a mismatch between transmission PTO shaft and engine on the machines listed above, it is necessary to
replace the PTO shaft and engine flywheel.
SERVICE PROCEDURE:
1 Position the machine on firm level ground. Engage the parking brake and select neutral. Lower the loader arms to
the ground, discharge the hydraulic system and stop the engine.
2 Disconnect battery.
3 Undo two hinge pivot bolts to release frame supporting condenser and hydraulic cooler, lay assembly on top of
battery box/counterweight.
4 Remove harness from rear worklights/reverse alarm rear cowling, lay over counterweight.
5 Remove receiver/drier from rear cowl, remove AC compressor from engine.
DO NOT DISCHARGE AC SYSTEM
6 Drain coolant, disconnecting hoses as required, remove engine cover, radiator, air cleaner, expansion bottle and
stack pipe as one assembly, ie. remove bolts A (2 off), B (1 off) and C (2 off) each side.
DO NOT DISMANTLE ENGINE COVER ASSEMBLY (Rear Grille, Side Covers, top Panel and Radiator).
7 Remove engine, leave transmission in place, remove existing flywheel and replace with new one.
Warranty Ref. No. - S471 Parts to be returned
Warranty time allowed - 12.0 Hour Closing Date - 3 Months from issue date
8 See section F pages 7.1, 7.2, 7.3, 7.4, 7.5 and 7.6 for removal of PTO shaft (item 11).
9 Replace engine etc., in reverse order.
Special tool required 892/00909.
Parts Required
Part Number Description Qty. Comment

04/801628 PTO Shaft 1 Claim as Fail Part
04/801629 Piston Ring 1
04/801630 Gasket 1
04/801632 Key 1
04/801626 Gasket 1
04/800128 Gasket 1
02/291208 Bolt ‘V’ Grade !/2in. UNF x 2in. 12
265/01525 Flywheel (Special 436) 1
A
A
B
C C
TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Feb. 1997
SUBJECT: 436 Hydraulic Pressures
MACHINES AFFECTED: 436 Machines up to Serial No. 533170
TO BE CARRIED OUT: INFORMATION ONLY
Instances have been reported of high hydraulic power requirements when prying out. The pump pressure settings
have therefore been changed to improve the situation.
SERVICE PROCEDURE:
Adjust pressure as described in Service Manual (9803/4160) pages E/36 - 1 and E/36-2.
bar kgf/cm2 lbf/in2

System control pressure (main pump relief valve) 250 ±5 255 ±5.1 3625 ±72.5
Standby pressure (secondary pump relief valve) 160 ±5 163 ±5.1 2320 ±72.5
TECHNICAL INDEX
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INFORMATION
engineer has a sound knowledge of safety procedures and has been trained in the (83/N. Am.)
SUBJECT: Rear Grille/Bodywork Support
MACHINES AFFECTED: 426 Machines up to Ser. No. 531190

436 Machines up to Ser. No. 533186
TO BE CARRIED OUT: INFORMATION ONLY
Instances have occurred of the rear grille/bodywork support cracking at the bottom mounting flange F, where it bolts to
the rear chassis with a clamping plate.
SERVICE PROCEDURE:
1 Park the machine on firm level ground, lower the
loader arms, stop the engine and engage the
parking brake.
2 Remove and discard existing clamping plate A.
3 Using existing bolts, fasten new L.H. spreader plate

B into position.
4 Making sure that the rear grille/bodywork support is

square to the chassis, using the spreader plate as a
template, drill two 11 mm holes in the rear
grille/bodywork support.
A
5 Secure using Bolts C, Washers E and Nuts D.
6 Repeat steps 2 to 5 for the R.H. side.
Parts Required
Item Part No. Qty Description
F
B 265/01645 1 Spreader Plate L.H.
265/01646 1 Spreader Plate R.H.
C 1315/0407Z 4 Bolt
D 1370/0303Z 4 Nut
E 1420/0008Z 8 Washer A B
TECHNICAL INDEX
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INFORMATION
engineer has a sound knowledge of safety procedures and has been trained in the (K78/N. Am.)
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Jun 1997
Page 1/2
SUBJECT Parts Required
Engine Oil Cooler Hoses
Item Part No Description Qty
MACHINES AFFECTED A 02/200861 Hose 1
426 & 436 Machines manufactured during December B 02/200862 Hose 1
1996 and January 1997 and fitted with Perkins C 02/200272 Gasket 2
Engines (see list overleaf)
U.K. ONLY - Parts to be returned.
TO BE CARRIED OUT
Immediately All other territories except U.K. - Parts to be retained for
one month after warranty claim submitted.
SERVICE ACTION
To renew the Engine Oil Cooler Hoses on the machines
specified on page 2.
SERVICE PROCEDURE
1 Park the machine on firm, level ground, apply the

parking brake and lower any attachments. Remove
the starter key.
2 Open the right side engine cover and clean the

engine as necessary.
C
3 Remove the hoses A and B. Clean off the remains
of old gaskets from the oil cooler flange Y and Y
lower housing Z.
4 Fit new hoses A and B. Fit new gaskets C, using a

light application of JCB Multi-gasket 4102/1212.
B
Tighten bolts W to 22 Nm.
6 Run the engine and check for leaks.

W
A
7 Check the engine oil level and correct as required.
C
W
Warranty Ref. No. - S621 (426)
S622 (436)
Warranty time allowed - 1.0 Hour

Z
Closing Date - One month from receipt of this bulletin.
Page 2 of 2 T.I. 6/023 (K78/N. Am.) Issue 1
A/C COMPANY MACHINE ENGINE A/C COMPANY MACHINE ENGINE
426 436
112 Gunn, Warley 531235 YB50519U644938B 126 TCH, Alfreton 533232 YB50581U642759B
118 Gunn, Altrincham 531245 YB50519U647157C 145 Watling, Leicester 533238 YB50581U643522B
329 Terra Stroj 531231 YB50519U644937B 167 BC Plant 533239 YB50581U642562B
332 Globus 531225 YB50519U642923B 307 JCB NWE 533244 YB50581U646544C

307 JCB NWE 533249 YB50581U647206C
341 Nickolaison & Larson 531234 YB50519U643229B
308 JCB Germany 533229 YB50581U642753B
377 JCB Maquinaria 531238 YB50519U646349C
311 Comasco 533236 YB50581U643517B
426 Maquiperu 531229 YB50519U643236B
341 Nickolaison & Larson 533241 YB50581U645559B
451 JCB Inc 531230 YB50519U643233B
451 JCB Inc 531233 YB50519U643231B 370 Bauma Austria 533252 YB50581U642754B
451 JCB Inc 531236 YB50519U643228B
451 JCB Inc 531243 YB50519U643230B 377 JCB Maquinaria 533235 YB50581U642760B
451 JCB Inc 531244 YB50519U643234B 377 JCB Maquinaria 533242 YB50581U646545C
451 JCB Inc 531249 YB50519U642927B
451 JCB Inc 531250 YB50519U643235B 451 JCB Inc 533233 YB50581U643523B
451 JCB Inc 533248 YB50581U643518B
461 Blackwood Hodge, SA 531239 YB50519U644682B 451 JCB Inc 533257 YB50581U643516B
451 JCB Inc 533258 YB50581U643515B
980 JCB France 531241 YB50519U647156C 451 JCB Inc 533259 YB50581U642755B
451 JCB Inc 533260 YB50518U642761B
1449 JCB Singapore 531237 YB50519U646348C
1449 JCB Singapore 531240 YB50519U647158C 950 JCB Italy 533230 YB50581U642758B
9991 UK Warranty 531228 YB50519U642926B 980 JCB France 533231 YB50581U643519B
1305 Distribuidora Yale 533237 YB50581U642563B
1449 JCB Singapore 533243 YB50581U645558B

1449 JCB Singapore 533250 YB50581U647207C
TECHNICAL INDEX
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INFORMATION
engineer has a sound knowledge of safety procedures and has been trained in the (E148/N. Am.)
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Jun 1997
Page 1/2
SUBJECT: Main Feed Pipe (Priority Valve to Valve Block)
MACHINES AFFECTED: 426 up to Machine Serial Number 531253

436 up to Machine Serial Number 533255
TO BE CARRIED OUT: FOR INFORMATION ONLY
Instances have occurred of the main feed hose across the centre pivot, putting high stresses into the feed pipe from
the priority valve, causing pipe failures.
SERVICE PROCEDURE:
1 Park the machine on firm, level ground and chock all four wheels. Lower attachments to the ground, install the
articulation safety link, switch off the engine and vent system pressure.
2 Remove hose clamps D and modify by removing hatched area as shown in Fig. 2. Retain fasteners.
3 Remove existing hose clamp bracket E and discard. Retain fasteners.
4 Fit new bracket 3 using existing fasteners.
5 Refit modified hose clamps F with servo loom B to the right and return hose C to the left, using existing fasteners.
6 Fit hose guide strap 1 to bracket 3 enclosing main feed hose A. Using Bolts 4, Washers 5 & 6 and Nuts 7.
7 Ensure servo loom B and return hose C are not pulled tight on full lock in either direction.
Parts Required
Item Part No. Description Qty
1 265/02046 Hose Guide Strap 1

2 265/02058 Hose Clamp Plate 1
3 268/30105 Hose Clamp Bracket 1
4 1315/0509Z Bolt 2
5 1412/0005Z Washer 2
6 1420/0009Z Washer 2
7 1370/0403Z Nut 2
Page 2 of 2 T.I. 6/024 (E148/N. Am.) Issue 1
Fig.1 Fig.2
44
136
45
E
50
D
Fig.3
6
5
4
7
3
F
1
F
2 B
C
A
TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Jul. 1997
Page 1/1
SUBJECT: Servo Control Update
MACHINES AFFECTED: 456B Machines up to Serial No. 539029 except 539018, 539024 & 539027.
TO BE CARRIED OUT: IMMEDIATELY
With the servo control lever in the arms lower position, a pressure build up is caused in the pressure reducing valve,
causing the arms to surge down.
SERVICE PROCEDURE:
2 Remove and discard hose A. Fit plug 1 at position B

on valve block.
3 Remove and discard plug from position C and fit 1

bonded washer 2 and adaptor 3.
4 Fit hose 4 between position C on valve block and

pressure reducing valve.
5 Reset servo pressure to 35 Bar (507.5 lbf/in2 ).
Parts Required
A
Item Part No. Description Qty B
C
1 816/00294 Plug 1 2 4
2 1406/0026 Bonded Washer 1
3
3 1606/0006 Adaptor 1
4 631/30600 Hose 1
Warranty Ref. No. - S634
Warranty time allowed - 0.5 Hour Closing Date - 1 Month from issue date
TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Jul. 1997
Page 1/1
SUBJECT: Hydraulic Filter Head
MACHINES AFFECTED: 426B, 436B & 456B
TO BE CARRIED OUT: FOR INFORMATION ONLY
Instances have occurred of the ‘O’ Ring groove in the filter head cover 1 being machined over-size,causing fluid
leakage between the filter head head housing and the cover.
SERVICE PROCEDURE:
Replace leaking cover with new item 1.
Parts Required
Item Part No. Description Qty
1 581/07004 Cover 1 1
TECHNICAL INDEX
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INFORMATION
JCB SERVICE for advice. Remember SAFETY MUST COME FIRST. Date Nov. 1997
Page 1/2
SUBJECT: Engine Coolant Expansion Tank
MACHINES AFFECTED: 456B Machines up to Ser. No. 539029
An improved expansion tank system has been introduced to improve the engine coolant filling procedure.
SERVICE PROCEDURE:
2 Allow the engine to cool then remove the coolant filler cap, worm drive clip 7 and hose 6 from expansion tank;
drain coolant, down to the level of worm drive clip 8, into a clean container
3 Remove items 1, 2, 3, 4, 5, 6, and 8 shown in Fig. 1.
4 Fit new expansion tank M.
5 Fit Adaptor A, adaptor B and venting adaptor C.
6 Reduce length of hoses D to 1250mm. Fit hoses to expansion tank, secure to engine cover using clamps E,cover
plates F, bolts G and locknuts H.
7 Fit free end of one hose to radiator and the free end of the other hose to venting adaptor C, secure using worm
drive clips L.
8 Fit new hose J, secure using worm drive clips K.
9 Drill three 9mm diameter holes as per fig. 2 and fit items E, F, G and H to secure coolant hoses D.
Note: Fig. 2 shows plan view of engine cover, left side of the machine. Measurements taken from rear edge.
10 Replenish the engine coolant, run the engine and check for leaks.
Warranty Ref. No. - S637 Warranty time allowed - 2.0 Hours
Closing Date - Three months from receipt of this bulletin.
Parts Required
Item Part No. Description Qty Item Part No. Description Qty
A 816/15146 Adaptor 1 G 1315/3310Z Bolt M8 x 40 3

B 816/30002 Adaptor 1 H 1370/0203Z Locknut 3
C 478/00224 Venting Adaptor 1 J 834/00774 Hose 1
D 648/00405 Hose 2 K 2201/0008 Worm Drive Clip 2
E 821/00347 Clamp 3 L 2201/0004 Worm Drive Clip 4
F 821/00335 Cover Plate 3 M 269/40214 Expansion Tank 1
Fig. 1
1 2
3
3 3
3 1
1 5
3
7
6
3
4 8
Fig. 2
9 mm
14 mm 200 mm 200 mm 725 mm
G L
E L
L D
F
H M
C D
L
B K
J K
A
TECHNICAL INDEX
R
INFORMATION
Page 1/6
SUBJECT: Priority Valve Installation
MACHINES AFFECTED: 436 Machines From Ser. No. 533001 to 533266
This improvement of the main hydraulic layout illiminates the need for high pressure feed pipes. This is achieved by
repositioning the priority valve into the front chassis and replacing the large feed hose with two smaller hoses.
SERVICE PROCEDURE: (Removal)

1 Park the machine on firm, level ground, apply
full right lock and chock all four wheels. Lower
attachments to the ground, switch off the
engine and vent system pressure. Open front
apron mat. A
2 Remove and discard the centre pivot hose A,
clamp or clamp and strap.
3 Disconnect hoses C, D, E & F attached to the

priority valve G.
D K C
4 Remove priority valve G, adaptor K and non
return valve J as an assembly. G
E B
5 Remove and discard feed pipe B and adaptor
K. Remove and retain non return valve J.
J
6 Remove existing feed pipe B support bracket, F

grind area to remove any sharp edges.
H
7 Remove and discard hoses D & E from main
and secondary pumps. Retain SAE flange
clamps H and bolts, ie. remove only two bolts H
and one clamp, leaving the other in place.
8 Remove and discard load sensing hose C H

from shuttle valve. H
Warranty Ref. No. - S658 (Ser. No. 533001 - 533069)
S660 (Ser. No. 533070 - 533266)
Service Code: E620*
Closing Date - Three months from receipt of this bulletin.
SERVICE PROCEDURE: (Assembly)
7 Fit threaded flange 37 to pressure port P on loader valve block. Make sure that the ‘O’ ring is fitted. Fully tighten
37.
Note: For machines 533001 to 533091 with UNC threads, use capscrews 36 from kit. Machines from 533092 with
metric threads use M12 capscrews supplied with item 37.
8 Place dowty washer 32 onto adaptor 35 and fit to threaded flange 37. Tighten fully.
Sub assemble the priority valve,
9 Fit adaptors 39 and 40 to priority valve G. Fit Tee adaptor 38 to adaptor 40, Finger tight only.
10 Fit priority valve G to bracket 21, fit clamp plate 22 to bracket 21. Do not tighten at this point.
Note: ‘LS’ port to be at the bottom.
11 Screw Tee adaptor 38 into adaptor 35, do not fully tighten.
Note: the priority valve is now supported by the adaptors to the valve block.
12 Position bracket 21 against the underside of the front chassis and mark the mounting points.
Note: It is important that the adaptors are sufficiently tight so that the priority valve does not move when they are fully
tightened. To prevent pre-loading the priority valve.
13 Remove bracket 21, drill and tap two holes M10 (thread engagement must be minimum of 15 mm).
14 Fit bracket 21 to the chassis and secure using screws 23 and washers 24.
15 Place dowty washer 31 onto adaptor 41 and fit to non return valve J. Place dowty washer 31 onto elbow 33.
Tighten fully.
Note: Make sure the direction of the non return valve is as shown.
16 Fit elbow 33 to Tee adaptor 38. Clamp into position using plate 25, stauf clamp 26, washers 28 and nuts 27.
17 Fully tighten the adaptors and brackets securing the priority valve.
Note: Take great care not to pre-load the priority valve.
18 Fit hose 1 to primary pump (P1), route through and fit to ‘P’ port of priority valve G . Fit hose 2 to secondary pump
(P2),route through and fit to adaptor 41. Make sure that the ‘O’ ring is in place on both hoses. Do not fully tighten
the the connectors at either end of both hoses at this point.
19 On machines 533001 to 533069, proceed as follows: Disconnect existing hose Z from emergency steer valve, fit
Tee adaptor 45, dowty washers 43, non return valve 44 and adaptor 42 as shown. Reconnect hose Z to Tee
adaptor 45.
On machines from 533070, proceed to step 20.
Note: Make sure hoses do not chafe on each other.

20 Fit hose 3 to adaptor 42 and to the ‘CF’ port on the priority valve.
Note: Under cab area, hose 3 runs underneath hoses 1 and 2.
21 Connect hose 4 to the ‘LS’ port on the priority valve and the shuttle valve located on the front face of the
transmission to the rear of the parking brake.
22 Fit clamps 19 and plate 20.
Note: Hose positions as follows (from top to bottom) Hose 3

Servo hoses
Tank return hose
Main pump feed 1
Secondary pump feed 2
23 Fit hose clamp bracket 13 and spacer tube 14, bracket 13 goes between spacer 14 and existing steady bracket
C. On machines up to 533050, If necessary use M20 plain washers to maintain alignment of brake caliper
bracket D.
24 Fit clamps 15 and plates 16. The hose phasing is critical. The length of hose between the centre clamping
position and the transmission bottom clamping should be such that the machine can go from lock to lock without
the hoses becoming taught, but not sagging to an extent where there is less than 65 mm clearance between the
hoses and the propshaft.
25 Fit Hose clamp top 46, hose clamp base 47 and hose clamp insert 48. Make sure that with the parking brake on,
the cable is not hard against the clamp.
26 Fit clamps 15 and plates 16. The hose phasing is critical. The length of hose between the transmission bottom
clamping and the transmission top clamping should be such that they give a minimum of 15-20 mm clearance
between the hose and the top edge of the chassis at the top, and that they are not chaffing on any sharp objects
particularly where the priority valve was fitted.
The connections at both ends of hoses 1 and 2 should now be tightened.
Note: If it is not possible to achieve the 15-20 mm clearance, cut away the flange. Do not interfere with the weld on
the underside of the plate.
As a guide, the clearance between the transmission and the edge of the chassis should be 60-65 mm.
Installation Check
Ensure that clearances are as specified.
Start the machine and operate the hydraulics. Make sure that there is no chafing of the hoses.
Turn the machine from lock to lock, make sure that the hoses 1 and 2 do not touch each other. Make sure that the
propshaft clearance of 65 mm is maintained.
Page 4 of 6
Fig. 1
X - To Emergency Steer Valve (‘P’ port)
Y - To Shuttle Valve
!@%^&
P1 ( )1
3
0
P2
!
2 5
J1
1
7
82 £$
9 X
4
1 4 ()
T.I. 6/028 (E157/N. Am.) Issue 1

1
Y
3 2 !@%^&
⁄‹›
0!@*
fifl‡°
!@¤·
Page 5 of 6
Fig. 2
$
Z
$ A
B
3 %
£ D
@ £ E
A - Emergency Steer Valve

£
B - Shuttle Valve
C - Existing Steady Bracket

^ &*
T.I. 6/028 (E157/N. Am.) Issue 1

D - Brake Caliper Mounting Bracket
E - Load Sense Hose From Priority Valve

Parts Required (Kit Part Number - 997/16800)
Item Description Qty. Item Description Qty. Item Description Qty.

1 Hose 1 22 Clamp Plate 1 39 Adaptor 1
2 Hose 1 23 Set Screw 2 40 Adaptor 1
3 Hose 1 24 Hardened Washer 2 41 Adaptor 1
4 Hose 1 25 Plate 1 46 Hose Clamp Top 1
10 Bolt 2 26 Stauff Clamp 1 47 Hose Clamp Base 1
11 Plain Washer 16 27 Lock Nut 2 48 Hose Clamp Insert 1
12 Lock Nut 8 28 Plan Washer 2 49 Hose Clamp Top 1
13 Hose Clamp Bracket 1 29 Bolt 2 50 Hose Clamp Base 1
14 Spacer Tube 1 31 Bonded Washer 2 51 Hose Clamp Insert 1
15 Hose Clamp Half 4 32 Dowty Washer 1
16 Clamp Plate 3 33 Elbow 1 Item Part No. Description Qty.
17 Bolt 4 34 Adaptor 90° 1 42 1604/0004 Adaptor 1
18 Hose Support Bracket 1 35 Adaptor 1 43 1406/0018 Dowty Washer 2
19 Hose Clamp Half 2 36 Cap Screw 4 44 25/905500 Check Valve 1
20 Clamp Plate 1 37 Threaded Flange 1 45 816/50005 Tee Adaptor 1
21 Priority Valve Bracket 1 38 Tee Adaptor 1
Under cab 48
showing position of 47
46
hose clamps circled.
‘P’ clip for parking brake

cable and shuttle valve.
B
Centre hose support

bracket.
Priority valve assembly

in front chassis.
Z NRV and Tee-adaptor

on Emergency Steer
Valve.
Hose Z
(See Fig. 2)
44 45
TECHNICAL
R
INFORMATION
Page 1/2
SUBJECT: Priority Feed Pipe
MACHINES AFFECTED: 426 Machines 531001 to 531253 Except 531245, 246, 247 & 248
TO BE CARRIED OUT: As required
An improved priority valve feed hose has been introduced.
SERVICE PROCEDURE:
1 Park the machine on firm, level ground, apply full right lock and chock all four wheels. Lower attachments to the
ground, switch off the engine and vent system pressure.
2 Remove and discard hose A and pipe B from bracket C.
3 Cut off existing bracket C as shown in Fig. 1.
4 Clamp bracket 2 as shown in Fig 2, drill holes and secure using bolts 8, washers 7 and nuts 6.
5 Fit hose 1 from priority valve to loader valve block.
6 Using bolts 5, washers 7 and nuts 6, fit hose clamp 3 and plate 4 to bracket 2 to support the hose.
7 If not already done, carry out T.I. 6/024 (E148/N. Am.).

Fig. 1 Fig. 2
C
8
7
6
1
C
5
4 3 3 2 6
7
Page 2 of 2 T.I. 6/029 (E156/ N. Am.) Issue 1
Parts Required

1 616/23300 Hose 1
2 265/02037 Bracket 1
3 821/00149 Clamp 1
4 821/00444 Plate 1
5 1315/3522Z Bolt 2
6 1370/0403Z Nut 4
7 1420/0009Z Washer 8
8 1315/0509Z Bolt 2
TECHNICAL INDEX
R
INFORMATION
Page 1/2
SUBJECT: Priority Feed Pipe
MACHINES AFFECTED: 426 Machines 531001 to 531253 Except 531245, 246, 247 & 248
TO BE CARRIED OUT: As required
An improved priority valve feed hose has been introduced.
SERVICE PROCEDURE:
1 Park the machine on firm, level ground, apply full right lock and chock all four wheels. Lower attachments to the
ground, switch off the engine and vent system pressure.
2 Remove and discard hose A and pipe B from bracket C. (If Adaptor 9 is fitted to priority valve, leave it in position)
3 Cut off existing bracket C as shown in Fig. 1.
4 Clamp bracket 2 as shown in Fig 2, drill holes and secure using bolts 8, washers 7 and nuts 6.
5 Fit hose 1 from priority valve to loader valve block.
6 Using bolts 5, washers 7 and nuts 6, fit hose clamp 3 and plate 4 to bracket 2 to support the hose.
7 If not already done, carry out T.I. 6/024 (E148/N. Am.).

Fig. 1 Fig. 2
C
8
7
6
1
C
5
4 3 3 2 6
7
Page 2 of 2 T.I. 6/029 (E156/ N. Am.) Issue 2
Parts Required

1 616/23300 Hose 1
2 265/02037 Bracket 1
3 821/00149 Clamp 1
4 821/00444 Plate 1
5 1315/3522Z Bolt 2
6 1370/0403Z Nut 4
7 1420/0009Z Washer 8
8 1315/0509Z Bolt 2
9* 816/15177 Adaptor 1
* Required on machines up to Ser. No. 531146.
If pipe 268/20076 has already been fitted, item 9 will also be fitted.
Check machine history file for information.

JCB Idle Control Update

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420,425,426,435,436 & 456 4/000

T. I. No. Machine F.S.I. Subject Date

SUBJECT: JCB CD90 Crownwheel Bolts Page 1 of 1

TO BE CARRIED OUT: For Information Only

1 Fit the crownwheel to the differential assembly as per

2 Fit 12.9 grade crownwheel bolts A, torque tighten

Note: Use only new Verbus Ripp bolts.

Item Part Number Description Qty

MACHINES AFFECTED: 426 Machines up to Serial Number 531051

2 Isolate the machine electrics.

3 Remove the insrument panel from the moulding.

7 Plug diode B into the 2 way plug on adaptor harness A.

Item Part No. Description Qty.

A 721/00034 Adaptor Harness 1

Warranty time allowed - 0.5 Hours

SUBJECT: Idle Control Page 1 of 4

6 Loose fit hose 11 to tee adaptor 12.

8 Tighten all hoses.

10 Install harness as per Fig. 2.

Idle Control Pressure 170 ± 5 bar

Pressure gauge 0-400 bar

Pressure Setting Procedure

Set idle speed as stated.

Adjust idle control proximity switch

1 Working underneath cab (engine off)pull throttle lever

2 Adjust proximity switch end gap so that the linkage Fig. 1

3 Roughly set proximity switch so that throttle lever leads Y

5 Adjust idle control valve Y (See fig. 2) as specified

6 Slowly depress throttle pedal and note engine speed

7 Adjust proximity switch to achieve specified cut off

8 Tighten proximity switch then recheck engine speed.

Check Machine Operation

Parts Required - (Order Kit Part No. 993/88700)

Item Part No. Description Qty.

Warranty time allowed - 1.5 Hours

SUBJECT: Idle Control Page 1 of 4

MACHINES AFFECTED: JCB 436 HT and ZX machines up to Ser. No. 533060

5 Remove pressure test adaptor from top of secondary pump.

7 Fit pressure test adaptor at bottom of secondary pump.

8 Connect hose 12 to top of secondary pump.

9 Connect hose 11 to top of shuttle valve.

10 Loose fit hose 11 to tee adaptor 13.

12. Tighten all hoses.

14 Install harness as per Fig. 2.

Engine speed to cut-in secondary pump 1150 - 1250 rpm.

Pressure gauge 0-400 bar

Pressure Setting Procedure

Set Steering to left hand lock

Set idle speed as specified in Service Manual.

Adjust idle control proximity switch

1 Working underneath cab (engine off)pull throttle lever Fig. 1

2 Adjust proximity switch end gap so that the linkage

3 Roughly set proximity switch mid-way in slot but do not

4 Start engine, operate arms lower.

5 Slowly depress throttle pedal and note engine speed

7 Tighten proximity switch then recheck engine speed.

Check ‘Boost’ Operation

Dead-head a service and check secondary pressure according to table:

Parts Required - (Order Kit Part No. 993/88800)

Item Part No. Description Qty.

1 Connect connector RA to solenoid valve. 5 Disconnect the connector on transmission dump