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1. SERVICE MANUAL
LOADER
427, 435S, 437
EN - 9813/6100 - ISSUE 4 - 03/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

2. 15 - Engine
12 - Crankshaft
27 - Damper
15 - 31 9813/6100-4 15 - 31
27 - Damper
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
engine has cooled sufficiently before you start
the removal.
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Support the damper.
5. Remove the screws (x6).
6. Remove the damper from the engine.
Figure 164.
A
B
A Damper
B Screws (x6)
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the screws to the correct torque value.
2.1. Use the torque and angle tightening
procedure. Refer to (PIL 72-00).
2.2. Make sure that you follow the correct
tightening sequence. Refer to Figure 165.
Figure 165.
6
4
25
3
1
Table 69. Torque Values
Description Torque Values
- first stage torque 50N·m
- second stage torque 90°

3. 15 - Engine
18 - Engine Belt
00 - General
15 - 33 9813/6100-4 15 - 33
00 - General
Introduction .................................................... 15-33
Health and Safety .......................................... 15-34
Component Identification ............................... 15-34
Introduction
A crankshaft pulley is used to drive a FEAD
(Front End Accessory Drive) belt. The belt drives
the coolant pump. Depending on the machine
application, the belt is configured to drive engine
mounted accessories, such as the alternator, cooling
fan and air conditioning compressor.
Some applications have a second pulley on the
crankshaft which drives a dedicated fan belt. The belt
drives an engine mounted cooling fan.

4. 15 - Engine
18 - Engine Belt
00 - General
15 - 34 9813/6100-4 15 - 34
Health and Safety
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
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.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
Component Identification
Figure 166.
A
F
D
E B
C
H
G
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper

5. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 35 9813/6100-4 15 - 35
03 - Drive Belt
Introduction .................................................... 15-35
Health and Safety .......................................... 15-36
Check (Condition) .......................................... 15-36
Adjust ............................................................ 15-37
Remove and Install ....................................... 15-37
Introduction
The crankshaft pulley is used to drive the coolant
pump via a FEAD (Front End Accessory Drive) belt.
In addition to the coolant pump the drive belt can
also be configured to drive the engine mounted
accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the necessary
belt/pulley contact area the belt is routed around
idler wheels as required. The configuration varies
depending on the accessories installed.

6. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 36 9813/6100-4 15 - 36
Health and Safety
Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts.
Check (Condition)
At the recommended service interval, visually inspect
the drive belt for damage.
1. Make the machine safe.
Refer to: PIL 01-03.
2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 167.
A
B
C
A Crack in belt
B Missing piece of belt
C Frayed belt

7. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 37 9813/6100-4 15 - 37
Adjust
Adjustment is not possible with this drive belt. A
spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct
tension.
Remove and Install
There are a number of drive belt routes. This
procedure does not include all of the routes. Do a
diagram of the drive belt route before removal to help
installation.
The belt tensioner is spring-loaded, it must be
pivoted away from the drive belt. Do not pivot the
belt tensioner in the wrong direction, this can cause
damage.
Make a note that too much force in the opposite
direction of wind-up or when the belt tensioner
is wound-up to the positive-stop, can cause the
tensioner arm to crack or break.
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Isolate the battery. Refer to (PIL 33-03).
3. Open the engine compartment cover. Refer to
(PIL 06-06).
4. Hold the tensioner against the spring force and
lift the belt off the drive tensioner pulley.
Figure 168.
A
F
D
E B
C
H
G
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper

8. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 38 9813/6100-4 15 - 38
Install
1. Use the diagram to correctly route the new drive
belt on the pulleys.
2. Pivot the belt tensioner in the direction of the
spring tang.
3. Install the new drive belt. Put the drive belt over
the water pump pulley last.
4. If it is difficult to install the drive belt, do as follows:
4.1. Put the drive belt over the grooved pulleys
first.
4.2. Hold the belt tensioner up and slide the
drive belt over the water pump pulley.
5. Slowly release the belt tensioner to apply tension
to the drive belt.
6. Check the alignment of the drive belt with the belt
tensioner and the other components.
7. Use the deflection method to measure the
tension in the drive belt.
7.1. Apply the specified force between the
pulleys on the drive belt.
Force: 110N
7.2. If the deflection is more than the thickness
of one drive belt per foot of pulley centre
distance, adjust the drive belt tension.
7.3. If there is too much movement of the drive
belt, replace it.
8. Close the engine compartment cover. Refer to
(PIL 06-06).
9. Run the engine and listen to hear if the drive belt
squeals.
9.1. Too much squeal indicates that the drive
belt is slipping too much.
9.2. Check the route of the drive belt to make
sure it is correctly installed over each pulley.

9. 15 - Engine
18 - Engine Belt
21 - Tensioner
15 - 39 9813/6100-4 15 - 39
21 - Tensioner
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Remove the capscrew.
5. Remove the belt tensioner from the engine.
6. If necessary, remove the bracket.
Figure 169.
A
B
A Belt tensioner
B Capscrew
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the capscrew to the correct torque value.
Table 70. Torque Values
Item Nm
B 43

10. 15 - Engine
21 - Oil Filter
00 - General
15 - 42 9813/6100-4 15 - 42
Health and Safety
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
Component Identification
Figure 170.
D
E
F
D Filter head
E Seal
F Filter canister

11. 15 - Engine
21 - Oil Filter
00 - General
15 - 43 9813/6100-4 15 - 43
Operation
At Engine Running
The oil pump delivers oil at pressure to the oil filter
via a port. The anti-drain seal is forced off its seat and
oil flows through a large area paper element. Filtered
oil enters the inner part filter before leaving the filter
head via a port.
At Engine Stopped
With the engine stopped oil pressure in the galleries
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents
approximately half the filters oil capacity from
draining. These features help protect the engine from
oil starvation on start up.
Check (Level)
1. Make the machine safe. Refer to (PIL 01-03).
2. Wait for the specified duration after the engine
has stopped before you check the oil level. This
gives time for the oil to drain into the oil sump.
Duration: 15min
3. Open the engine compartment cover. Refer to
(PIL 06-06).
4. Remove the dipstick. Refer to Figure 171.
Figure 171.
A
B
A Dipstick
B Filler cap
5. Check that the oil level is between the two marks
on the dipstick.
6. Never operate the engine with the oil level below
the low mark or above the high mark. Poor
engine performance or damage can occur.
7. If necessary, add oil as follows:
7.1. Remove the filler cap. Refer to Figure 171.
7.2. Add the recommended oil through the filler
point until it is at the correct level on the
dipstick.
8. Install the dipstick.
9. Install the filler cap.
10. Close the engine compartment cover. Refer to
(PIL 06-06).

12. 15 - Engine
21 - Oil Filter
00 - General
15 - 44 9813/6100-4 15 - 44
Remove and Install
Remove
1. Make the machine safe with the lift arm lowered.
Refer to PIL (01-03).
2. Open the engine compartment cover. Refer to
PIL (06-06).
3. Remove the filler cap.
4. Drain the engine oil as follows:
4.1. Make sure that the engine is warm.
4.2. Put a suitable container underneath of the
drain hose.
4.3. Connect the drain hose to the quick release
coupling.
4.4. Allow oil to drain.
4.5. Disconnect the drain hose from the quick
release coupling.
Figure 172.
A
B
A Quick release coupling
B Drain hose
5. Remove the filter canister.
6. Make a note that the filter canister will be full of
oil.
7. Clean the surface of the gasket on the filter head.
Figure 173.
D
E
F
D Filter head
E Seal
F Filter canister
Install
1. Fill the new filter canister with the correct grade
of oil. Refer to (PIL 75-03).
2. Make sure that the oil filters are installed with a
filter bypass valve.
3. Apply a thin layer clean oil to the seal.
4. Install the seal on the new filter canister.
5. Install the new filter canister until it just touches
the filter head.
6. Rotate the filter canister to further 3/4 of a turn.
Refer to Figure 174.
Figure 174.
7. Top up the correct grade of oil through the filler
neck. Refer to (PIL 75-03).
8. Install the filler cap.
9. Close the engine compartment cover. Refer to
PIL (06-06).
10. Start the engine.
10.1. If there is no oil pressure within the
specified duration after the engine is

13. 15 - Engine
21 - Oil Filter
00 - General
15 - 45 9813/6100-4 15 - 45
started, stop the engine to decrease the
risk of engine damage.
Duration: 15s
11. Check the system for leaks.
12. Stop the engine.
13. Let the engine cool for specified duration.
Duration: 10min
14. Check the oil level again.

14. 15 - Engine
24 - Air Filter
00 - General
15 - 48 9813/6100-4 15 - 48
Health and Safety
Notice: Do not run the engine when the element
has been removed.
Notice: The outer element must be renewed
immediately if the warning light on the instrument
panel illuminates.
Check (Condition)
The air filter element (s) should be changed at
the recommended service interval, refer to the
Maintenance Schedules. Refer to (PIL 78-24).
Check all the hose connections for loose installations
and damaged hose clamps, look specifically for splits
or cracks in the hoses. Pay particular attention to the
connections on the air intake to turbo compressor
and on the crossover tube.
Renew any damaged components.
In addition, most air filter housings will be installed
with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.

15. 15 - Engine
24 - Air Filter
00 - General
15 - 49 9813/6100-4 15 - 49
Remove and Install
Remove
1. Make the machine safe with the lift arm lowered.
Refer to (PIL 01-03).
2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Loosen the clamp and disconnect the hose.
Refer to Figure 175.
Figure 175.
A
B
C
A Air filter
B Clamp
C Hose
4. Inspect the hose, as follows:
4.1. If damaged, replace the hose.
4.2. Make sure that the hose is free from
contamination.
4.3. If the hose is plugged or full of contaminant
then use a low volume of compressed air to
clean it.
5. Open the retention latches (x4).
6. Carefully remove the filter cover in an upward
direction. Refer to Figure 176.
6.1. Use suitable ladder to access the air filter.
7. Push down the filter with the handle 1 and loosen
the seal. This will tilt the filter then remove the
filter element in an upward direction. Refer to
Figure 176.

16. 15 - Engine
24 - Air Filter
00 - General
15 - 50 9813/6100-4 15 - 50
Figure 176.
D
D
E
E
F
F
G
G
D Retention latches E Filter cover
F Handle 1 G Filter element
8. Inspect the safety filter, as follows: Refer to
Figure 177.
8.1. Remove any excess dirt and wipe out the
housing with a damp cloth.
8.2. Visually inspect the safety filter.
8.3. Do not remove it unless it is damaged or
due for replacement. The safety filter should
be replaced after every three primary filter
changes.
9. If necessary, remove the safety filter as follows:
Refer to Figure 177.
9.1. Use the plastic handle on the face of the
safety filter.
9.2. Pull the filter towards the centre of the
housing and remove it.
Figure 177.
J
H
H Safety filter element
J Handle 2

17. 15 - Engine
24 - Air Filter
00 - General
15 - 51 9813/6100-4 15 - 51
9.3. Make sure that the outlet tube sealing area
is clean and undamaged.
9.4. If the safety filter is removed and the new
filter is not to be installed immediately, be
sure to cover the seal tube with a cloth to
avoid contamination.
9.5. Wipe the air cleaner housing interior with a
clean damp cloth.
Install
1. The installation procedure is the opposite of the
removal procedure.
2. Visually check for cuts, tears, or indentations on
the sealing surfaces before installation. If any
damage is visible, do not install.
3. Make sure that the inlet and outlet connections
are in good condition. Replace the rubber
connectors if necessary and reset the service
indicator.

18. 15 - Engine
24 - Air Filter
09 - Dust Valve
15 - 52 9813/6100-4 15 - 52
09 - Dust Valve
Check (Condition)
The dust valve allows any water in the hose to drain
away. It is recommended to inspect the dust valve,
every time you change the air filter. Refer to (PIL
78-24).
1. Make the machine safe. Refer to (PIL 01-03).
2. Isolate the battery. Refer to (PIL 33-03).
3. Open the engine compartment cover. Refer to
(PIL 06-06).
4. Remove the cooling bay covers. Refer to (PIL
06-06).
5. Loosen the clamp 1 (x2).
6. Remove the T-piece from the hose 1 and hose 2
with the dust valve.
7. If necessary, remove the hose 1.
7.1. Loosen the clamp 2.
7.2. Disconnect the hose 1.
8. Remove the dust valve from the T-piece.
Figure 178.
D
G
C
E
C
B
A F
A Dust valve
B T-piece
C Clamp 1 (x2)
D Hose 1
E Clamp 2
F Hose 2
G Air filter
9. Clean the dust valve and the T-piece.
10. Make sure that the dust valve and the T-piece are
not damaged. If necessary, replace them.
11. Check the condition of the hoses. If necessary,
replace them.
12. Install the dust valve to the T-piece.
13. If removed, install the hose 1.
13.1. Connect the hose 1.
13.2. Install the clamp 2.
14. Install the T-piece at its correct position.
15. Install the clamp 1 (x2).

19. 15 - Engine
27 - Crankcase Ventilation Filter
00 - General
15 - 56 9813/6100-4 15 - 56
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Open the engine compartment access cover.
Refer to (PIL 06-06).
4. Remove the oil filler cap.
5. Remove the capscrews.
6. Remove the CCV (Crankcase Ventilation) filter
cover.
7. Remove the CCV filter from the rocker cover.
8. Do not disturb the CCV filter gasket located on
the rocker cover.
9. If damaged, remove and discard the gasket.
Figure 179.
B
C
ADE
A CCV filter
B Capscrews
C Oil filler cap
D Gasket
E Rocker cover
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the capscrews to the correct torque
value.
Table 71. Torque Values
Item Nm
B 7

20. 15 - Engine
63 - Mount
00 - General
15 - 59 9813/6100-4 15 - 59
00 - General
Introduction .................................................... 15-59
Remove and Install ....................................... 15-60
Introduction
Engine mounts support the engine and in some
cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations and
noise are not transmitted to the rest of the machine.
Most engine mounts consist of metal attachment
plates and large rubber insulator blocks. The rubber
portions of the mount are flexible and provide the
cushioning that dampens the engine vibrations.
The metal bracket part of the mount provides the
mechanical support and attachment points for the
engine mounts.

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22. 15 - Engine
63 - Mount
00 - General
15 - 60 9813/6100-4 15 - 60
Remove and Install
Consumables
Description Part No. Size
4004/0501A 0.4L
4004/0502 5L
Waxoyl
4004/0505 200L
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine front mount from the
machine as follows:
Figure 180.
D
A
F
B
C
E
A Engine B Bush (x4)
C Washer 1 (x8) D Bolt 1 (x4)
E Locknut 1 (x4) F Front mount
3.1. Remove the bolt 1 (x4), locknut 1 (x4) and
washers 1 (x8).
3.2. Remove the spacers (x2).
3.3. Make a note that the engine front mounts
cannot be removed from the engine.
4. Remove the engine rear mount from the machine
as follows:

23. 15 - Engine
63 - Mount
00 - General
15 - 61 9813/6100-4 15 - 61
Figure 181.
K
L U
G
Q
H
R
M
S
T
J
N
P
G Rear mount plate H Resilient mount
J Locking plate (x2) K Bolt 2 (x2)
L Washer 2 (x2) M Locknut 2 (x2)
N Bolt 3 (x4) P Washer 3 (x4)
Q Locknut 3 (x8) R Setscrew (x8)
S Overload washer T Rebound washer
U Boss
4.1. Remove the setscrews (x8) and locknut 3
(x8).
4.2. Lift the engine and transmission assembly
away from the machine. Refer to (PIL
15-00).
4.3. Use a suitable stand to support the engine
and transmission assembly.
4.4. Remove the bolt 2 (x2), locknut 2 (x2) and
washers 2 (x2).
4.5. Remove the rebound washer, resilient
mount and overload washer.
4.6. Remove the bolt 3 (x4), washers 3 (x4) and
locking plate (x2).
4.7. Collect the boss (x4).
4.8. Remove the rear mount plate from the
transmission.

24. 15 - Engine
63 - Mount
00 - General
15 - 62 9813/6100-4 15 - 62
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Apply locking fluid to the bolt 2 before installation.
Consumable: Waxoyl
3. Tighten the nuts to the correct torque value.
4. Apply Waxoyl to the bolt 3 after you tighten it.
Table 72. Torque Values
Item Nm
D 43
K 360
N 520
R 44