service repair manual

1. SERVICE MANUAL
LOADER
432ZX PLUS
EN - 9823/0650 - ISSUE 1 - 05/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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
00 - Engine
00 - General
15 - 3 9823/0650-1 15 - 3
00 - General
Introduction ...................................................... 15-3
Component Identification ................................. 15-4
Drain and Fill ................................................... 15-9
Clean ............................................................... 15-9
Introduction
This section contains basic information about the
engine. For details of the maintenance procedures,
refer to supplier manual.
Make sure that the correct engine service tools,
consumables and torque figures are used when you
perform service procedures. Refer to: PIL 78-94-12.
Renewal of oil seals, gaskets, etc, and any
component showing obvious signs of wear or
damage is expected as a matter of course. It
is expected that components will be cleaned and
lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The 6 cylinder diesel engine has fuel ignited by
compression ignition (C.I.). The engine operates on
a four stroke cycle.
The engine is started by an electric starter motor. The
starter motor turns the engine via a pinion and teeth
on the engine flywheel.
Refer to: PIL 15-75.
When the engine runs the crankshaft drives the
camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 24 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a mechanical high
pressure fuel pump via gears.
Air is drawn into the engine via the inlet manifold,
and exhaust gases exit via the exhaust manifold. The
engine uses a turbocharger which pressurises the air
at the inlet manifold.
A mechanical lubrication oil pump is driven by
the crankshaft via gears. The pump pressurises
and circulates oil for engine lubrication and cooling
purposes.
A drive belt driven by the crankshaft, drives a
coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.

3. 15 - Engine
00 - Engine
00 - General
15 - 4 9823/0650-1 15 - 4
Component Identification
Figure 90. Front View
H
K
M
P
N
A
B
C
D
E
F
G
L
J
A Water outlet connection B Air intake
C Crankcase breather D Gear case cover
E Belt F Fuel inlet
G Engine front support H Oil sump
J Vibration damper K Turbo compressor outlet
L Belt tensioner M Alternator
N Exhaust outlet P Fan pulley

4. 15 - Engine
00 - Engine
00 - General
15 - 5 9823/0650-1 15 - 5
Figure 91. Rear View
G
A
B
C
E
D
F
A Rear engine bracket B Valve cover
C Exhaust outlet D Flywheel housing
E Flywheel F Oil sump
G Fuel inlet

5. 15 - Engine
00 - Engine
00 - General
15 - 6 9823/0650-1 15 - 6
Figure 92. Right Side View
L
F
C D
E
G
B
A
K
J
H
A Turbocharger B Manifold - exhaust
C Valve cover D Lifting point
E Alternator F Water inlet connection
G Engine oil cooler H Crankcase
J Engine oil drain K Oil sump
L Flywheel housing

6. 15 - Engine
00 - Engine
00 - General
15 - 7 9823/0650-1 15 - 7
Figure 93. Left Side View
L
A
B
D
G
E
F
C
K
J H
A Fuel pump B Valve cover
C Cam follower cover D Magnetic pick-up
E Flywheel housing F Fuel filter
G Starter motor H Fuel inlet
J Oil sump K Oil level gauge
L Crankcase

7. 15 - Engine
00 - Engine
00 - General
15 - 8 9823/0650-1 15 - 8
Figure 94. Top View
A
B
D E
J
K
G
H
F
C
A Alternator B Manifold - exhaust
C Air intake D Turbocharger
E Exhaust outlet F Valve cover
G Flywheel housing H Magnetic pick-up
J Fuel inlet K Fuel pump

8. 15 - Engine
00 - Engine
00 - General
15 - 9 9823/0650-1 15 - 9
Drain and Fill
Refer to: PIL 15-21-00.
Clean
Notice: Clean the engine before you start engine
maintenance. Obey the correct procedures.
Contamination of the fuel system will cause
damage and possible failure of the engine.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine
is to be washed using a high pressure system.
Make sure that the alternator, starter motor and
any other electrical components are shielded
and not directly cleaned by the high pressure
cleaning system. Do not aim the water jet directly
at bearings, oil seals or the engine air induction
system.
Before carrying out any service procedures that
require components to be removed, the engine must
be properly cleaned.
Cleaning must be carried out either in the area of
components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one
hour. DO NOT attempt to clean any part of the engine
while it is running.
1. Make sure that the electrical system is isolated.
2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
Length/Dimension/Distance: 600 mm

9. 15 - Engine
00 - Engine
00 - General
15 - 10 9823/0650-1 15 - 10
9. When the pressure washing is complete move
the machine away from the wash area, or
alternatively, clean away the material washed
from the machine.
10. Before working on specific areas of the engine
use a compressed air jet to dry off any moisture.
When the area is dry use a soft clean brush to
remove any sand or grit particles that remain.
11. When removing components be aware of any
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before
proceeding.
Additional cleaning must be carried out prior to
working on the high pressure fuel system. Refer to:
PIL 18-00-00.

10. 15 - Engine
21 - Oil Filter
00 - General
15 - 20 9823/0650-1 15 - 20
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.
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.

11. 15 - Engine
21 - Oil Filter
00 - General
15 - 21 9823/0650-1 15 - 21
Check (Level)
WARNING Never check the oil level or add
oil with the engine running. Be careful of hot
lubricating oil. Danger of scalding.
Notice: Do not exceed the maximum level
of engine oil in the sump. If the maximum is
exceeded, the excess must be drained to the
correct level. An excess of engine oil could cause
the engine speed to increase rapidly without
control.
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Wait for the oil to drain back into the engine sump
before you take a reading. If not, a false low
reading may be recorded which can cause the
engine to be overfilled.
3. Get access to the engine compartment (if
applicable).
Refer to: PIL 06-06-06.
4. Remove and clean the dipstick.
Refer to: PIL 01-09-12.
5. Put the dipstick into the tube then remove the
dipstick.
6. Check the oil level. The oil should be between
the two marks on the dipstick.
7. If necessary, add more oil:
7.1. Remove the filler cap.
Refer to: PIL 01-09-12.
7.2. Add the recommended oil slowly through
the filler point
Refer to: PIL 75-00-00.
7.3. Install the filler cap and make sure it is tight.
8. Close and secure the engine cover (if
applicable).
Remove and Install
CAUTION Oil will gush from the hole when the
drain plug is removed. Keep to one side when you
remove the plug.
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.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained
with the oil.
Figure 95.
B
A
A Drain plug (Sump)
B O-ring
Figure 96.
C
D
E
C Drain tube
D Oil filter canister
E Filter housing drain plug
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. Get access to the engine compartment.
Refer to: PIL 06-06-06.
3. Place a suitable container below the drain plug.

12. 15 - Engine
21 - Oil Filter
00 - General
15 - 22 9823/0650-1 15 - 22
4. Drain the oil into a suitable container:
4.1. Remove the drain plug.
4.2. Remove and discard the O-ring and let the
oil drain.
5. When the oil has completely drained:
5.1. Clean the drain plug. Install the drain plug
with a new O-ring. Tighten the drain plug to
the correct torque value.
6. Remove the filter canister.
6.1. Use a chain wrench if necessary.
7. Clean the seal face of the filter head.
8. Smear the new seal on the new filter canister with
clean engine oil.
9. Install and tighten the new filter canister until the
seal just contacts the filter head and then tighten
the filter canister at least 3/4 of a turn.
10. Add the correct specification and quantity of oil
through one of the filler points to the maximum
mark on the dipstick.
Refer to: PIL 75-00-00.
10.1. Clean any spilt oil.
11. Install the filler cap and make sure it is secure.
12. Operate the engine at idle speed until the oil
pressure low warning light has extinguished and
the new filter primed before the engine speed is
increased above idle speed.
13. Check for leaks.
14. Check the oil level when the oil has cooled.
14.1. Replenish with specific engine oil, if
necessary.

13. 15 - Engine
24 - Air Filter
00 - General
15 - 25 9823/0650-1 15 - 25
00 - General
Introduction .................................................... 15-25
Health and Safety .......................................... 15-26
Clean ............................................................. 15-26
Check (Condition) .......................................... 15-29
Remove and Install ....................................... 15-30
Introduction
Engine performance and durability will be severely
affected if the quality of the air intake is poor.
A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
which can cause engine mis-firing, black smoke and
low output power.
A dirty and blocked air filter can also lead to abrasion
of the cylinder bores and valves (referred to as
dusting). This will cause excessive oil consumption,
black smoke, low output power and a reduced engine
life.
In hostile environments, change the air filter
elements more frequently.
In some applications, an air filter pre-cleaner can be
installed.

14. 15 - Engine
24 - Air Filter
00 - General
15 - 26 9823/0650-1 15 - 26
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.
Clean
When the red band appears in the service indicator
of the air filter, you must replace the primary element.
During the third service interval you must replace the
safety element from the air cleaner assembly.
Figure 97.
A
A Air filter indicator
1. Make the machine safe.
Refer to: PIL 01-03-27.
2. You must not start the engine when the filter
element or piping is removed.
3. Always install a new filter element, it is not
recommended to clean the filter element.
4. Disengage the clamp and remove the top cover.
Figure 98.
C
B
B Clamp
C Top cover
5. Gently twist the end of the filter to disengage the
seal.
5.1. Remove the filter element from the housing.

15. 15 - Engine
24 - Air Filter
00 - General
15 - 27 9823/0650-1 15 - 27
Figure 99.
D
D Filter element
6. Clean the sealing surface and inside the air
cleaner housing
Figure 100.
E
E Safety element
7. Gently press the new filter element into the
housing.
Figure 101.
F
F Filter element
8. Make sure that you apply a gentle force from the
outer periphery.
Figure 102.
9. Install the top cover as follows.
9.1. Place the top cover on the housing.

16. 15 - Engine
24 - Air Filter
00 - General
15 - 28 9823/0650-1 15 - 28
Figure 103.
G
H
G Top cover
H Clamp
9.2. Make sure that the dust evacuator valve
faces downwards.
Figure 104.
J
J Dust evacuator valve
9.3. Engage the clamp.
10. Make sure that you reset the restriction indicator.
It will allow the red band to go back.
Figure 105.

17. 15 - Engine
24 - Air Filter
00 - General
15 - 29 9823/0650-1 15 - 29
Figure 106. 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.

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19. 15 - Engine
24 - Air Filter
00 - General
15 - 30 9823/0650-1 15 - 30
Remove and Install
Note: Do not attempt to wash or clean the elements,
they must only be renewed.
Note: A new inner element must be installed at least
every other time the outer element is changed. As a
reminder, mark the inner element with a felt tipped
pen each time the outer element is changed.
A typical air filter is shown below.
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Depress the clips and lift off the cover.
4. Turn the filter and disengage the seal.
5. Remove the outer element. Take care not to tap
or knock the element.
6. If the inner element is to be changed, lift up and
pull to remove the inner element.
Figure 107.
A
B
A Outer element
B Inner element
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
1.1. Clean inside the housing, and cover, make
sure that the air holes are clear.
1.2. Install the cover and fasten the latch. Make
sure that the dust valve is at the bottom.

20. 15 - Engine
24 - Air Filter
09 - Dust Valve
15 - 31 9823/0650-1 15 - 31
09 - Dust Valve
Clean
Important: Do not run the engine with the dust valve
removed.
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Make sure that the dust valve is not blocked.
4. Inspect the rubber flaps for cuts and nicks.
4.1. Make sure that the rubber has not perished.
5. If necessary, replace the dust valve.
Figure 108.
A
A Dust valve