JCB 427, 435S, 437 Wheel Loader Service Repair Manual Instant Download (427 SN 2311946 and up; 435S SN 22356576 and up; 437 SN 22312947 and up)

1
Foreword
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
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
Handling 06 - Body and Framework 09 - Operator
Station
and Load
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
27 - Damper Remove and Install
Figure 165.
Remove
6
1

• Make the machine safe. Refer to (PIL 01-03).
• 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.
• Remove the engine drive belt. Refer to (PIL
  15-18).
• Support the damper.
• Remove the screws (x6).
• Remove the damper from the engine.
• Figure 164.

4
3
2
5
Table 69. Torque Values
Description Torque Values
- first stage torque 50Nm
- second stage torque 90
A
B

• Damper
• Screws (x6)
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the screws to the correct torque value.
• Use the torque and angle tightening procedure.
  Refer to (PIL 72-00).
• Make sure that you follow the correct tightening
  sequence. Refer to Figure 165.

15 - 31
9813/6100-4
15 - 31
3
15 - Engine 18 - Engine Belt 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-33 Health and Safety
..........................................
15-34 Component Identification ...................
............ 15-34
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.
9813/6100-4
15 - 33
4
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5
15 - Engine 18 - Engine Belt 00 - General
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.
D
B
E
C G F
H
A

1. Crankshaft pulley
2. Fan pulley
3. Water pump pulley
4. Compressor installation location
5. Alternator pulley
6. Belt tensioner pulley
7. Belt tensioner
8. Vibration rubber damper

6
15 - Engine 18 - Engine Belt 03 - Drive Belt
03 - Drive Belt
Introduction
Introduction .....................................
............... 15-35 Health and Safety
..........................................
15-36 Check (Condition) ..........................
................ 15-36 Adjust ....................
........................................ 15-37
Remove and Install ...............................
........ 15-37
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.
7
15 - Engine 18 - Engine Belt 03 - Drive Belt
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.

• Make the machine safe. Refer to PIL 01-03.
• Stop the engine and let it cool down.
• Renew the drive belt if it has cracks or if it is
  frayed or has pieces of material missing.
• Figure 167.
• B
• A

• C
• Crack in belt
• Missing piece of belt
• Frayed belt

8
15 - Engine 18 - Engine Belt 03 - Drive Belt
Adjust
Remove and Install
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.
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
• Make the machine safe. Refer to (PIL 01-03).
• Isolate the battery. Refer to (PIL 33-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Hold the tensioner against the spring force and
  lift the belt off the drive tensioner pulley.
• Figure 168.

D
B
E
C G F
H
A

1. Crankshaft pulley
2. Fan pulley
3. Water pump pulley
4. Compressor installation location
5. Alternator pulley
6. Belt tensioner pulley
7. Belt tensioner
8. Vibration rubber damper

9
15 - Engine 18 - Engine Belt 03 - Drive Belt

• Install
• Use the diagram to correctly route the new drive
  belt on the pulleys.
• Pivot the belt tensioner in the direction of the
  spring tang.
• Install the new drive belt. Put the drive belt
  over the water pump pulley last.
• If it is difficult to install the drive belt, do
  as follows
• Put the drive belt over the grooved pulleys
  first.
• Hold the belt tensioner up and slide the drive
  belt over the water pump pulley.
• Slowly release the belt tensioner to apply
  tension to the drive belt.
• Check the alignment of the drive belt with the
  belt tensioner and the other components.
• Use the deflection method to measure the tension
  in the drive belt.
• Apply the specified force between the pulleys on
  the drive belt.
• Force 110N
• If the deflection is more than the thickness of
  one drive belt per foot of pulley centre
  distance, adjust the drive belt tension.
• If there is too much movement of the drive belt,
  replace it.
• Close the engine compartment cover. Refer to
  (PIL 06-06).
• Run the engine and listen to hear if the drive
  belt squeals.
• Too much squeal indicates that the drive belt is
  slipping too much.
• Check the route of the drive belt to make sure
  it is correctly installed over each pulley.

10
15 - Engine 18 - Engine Belt 21 - Tensioner

• 21 - Tensioner
• Remove and Install
• Remove
• Make the machine safe. Refer to (PIL 01-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Remove the engine drive belt. Refer to (PIL
  15-18).
• Remove the capscrew.
• Remove the belt tensioner from the engine.
• If necessary, remove the bracket.
• Figure 169.

A
B

• Belt tensioner
• Capscrew
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the capscrew to the correct torque value.
• Table 70. Torque Values

Item Nm
B 43
11
15 - Engine 21 - Oil Filter 00 - General
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
F
E

1. Filter head
2. Seal
3. Filter canister

9813/6100-4
15 - 42
12
15 - Engine 21 - Oil Filter 00 - General
Operation
Check (Level)

• Make the machine safe. Refer to (PIL 01-03).
• 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
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Remove the dipstick. Refer to Figure 171.
• Figure 171.

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.
A
B

• Dipstick
• Filler cap
• Check that the oil level is between the two marks
  on the dipstick.
• Never operate the engine with the oil level below
  the low mark or above the high mark. Poor
  engine performance or damage can occur.
• If necessary, add oil as follows
• Remove the filler cap. Refer to Figure 171.
• Add the recommended oil through the filler point
  until it is at the correct level on the
  dipstick.
• Install the dipstick.
• Install the filler cap.
• Close the engine compartment cover. Refer to
  (PIL 06-06).

9813/6100-4
15 - 42
13
15 - Engine 21 - Oil Filter 00 - General
Remove and Install
Figure 173.
Remove

• Make the machine safe with the lift arm lowered.
  Refer to PIL (01-03).
• Open the engine compartment cover. Refer to PIL
  (06-06).
• Remove the filler cap.
• Drain the engine oil as follows
• Make sure that the engine is warm.
• Put a suitable container underneath of the drain
  hose.
• Connect the drain hose to the quick release
  coupling.
• Allow oil to drain.
• Disconnect the drain hose from the quick release
  coupling.
• Figure 172.

D
F
E

1. Filter head
2. Seal
3. Filter canister

Install

• Fill the new filter canister with the correct
  grade of oil. Refer to (PIL 75-03).
• Make sure that the oil filters are installed with
  a filter bypass valve.
• Apply a thin layer clean oil to the seal.
• Install the seal on the new filter canister.
• Install the new filter canister until it just
  touches the filter head.
• Rotate the filter canister to further 3/4 of a
  turn. Refer to Figure 174.
• Figure 174.

B
A

• Quick release coupling
• Drain hose
• Remove the filter canister.
• Make a note that the filter canister will be full
  of oil.
• Clean the surface of the gasket on the filter
  head.

1. Top up the correct grade of oil through the
   filler neck. Refer to (PIL 75-03).
2. Install the filler cap.
3. Close the engine compartment cover. Refer to PIL
   (06-06).

• Start the engine.
• If there is no oil pressure within the specified
  duration after the engine is

9813/6100-4
15 - 42
14
15 - Engine 21 - Oil Filter 00 - General

• started, stop the engine to decrease the risk of
  engine damage.
• Duration 15s
• Check the system for leaks.
• Stop the engine.
• Let the engine cool for specified duration.
  Duration 10min
• Check the oil level again.

9813/6100-4
15 - 42
15
15 - Engine 24 - Air Filter 00 - General
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.
9813/6100-4
15 - 48
16
15 - Engine 24 - Air Filter 00 - General
Remove and Install
Remove

• Inspect the hose, as follows
• If damaged, replace the hose.
• Make sure that the hose is free from
  contamination.
• If the hose is plugged or full of contaminant
  then use a low volume of compressed air to clean
  it.
• Open the retention latches (x4).
• Carefully remove the filter cover in an upward
  direction. Refer to Figure 176.
• Use suitable ladder to access the air filter.
• 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.

• Make the machine safe with the lift arm lowered.
  Refer to (PIL 01-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Loosen the clamp and disconnect the hose. Refer
  to Figure 175.
• Figure 175.

A
B
C
A Air filter B Clamp C Hose
9813/6100-4
15 - 48
17
15 - Engine 24 - Air Filter 00 - General
Figure 176.
E
D
D
E
F
G
G
F
D Retention latches F Handle 1
E Filter cover G Filter element

• Inspect the safety filter, as follows Refer to
  Figure 177.
• Remove any excess dirt and wipe out the housing
  with a damp cloth.
• Visually inspect the safety filter.
• Do not remove it unless it is damaged or due for
  replacement. The safety filter should be
  replaced after every three primary filter
  changes.
• If necessary, remove the safety filter as
  follows Refer to Figure 177.
• Use the plastic handle on the face of the safety
  filter.
• Pull the filter towards the centre of the
  housing and remove it.

Figure 177.
H
J
H Safety filter element J Handle 2
9813/6100-4
15 - 48
18
15 - Engine 24 - Air Filter 00 - General

• Make sure that the outlet tube sealing area is
  clean and undamaged.
• 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.
• Wipe the air cleaner housing interior with a
  clean damp cloth.
• Install
• The installation procedure is the opposite of the
  removal procedure.
• Visually check for cuts, tears, or indentations
  on the sealing surfaces before installation. If
  any damage is visible, do not install.
• Make sure that the inlet and outlet connections
  are in good condition. Replace the rubber
  connectors if necessary and reset the service
  indicator.

9813/6100-4
15 - 48
19
15 - Engine 24 - Air Filter 09 - Dust Valve
09 - Dust Valve Check (Condition)

• Check the condition of the hoses. If necessary,
  replace them.
• Install the dust valve to the T-piece.
• If removed, install the hose 1.
• Connect the hose 1.
• Install the clamp 2.
• Install the T-piece at its correct position.
• Install the clamp 1 (x2).

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).

• Make the machine safe. Refer to (PIL 01-03).
• Isolate the battery. Refer to (PIL 33-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Remove the cooling bay covers. Refer to (PIL
  06-06).
• Loosen the clamp 1 (x2).
• Remove the T-piece from the hose 1 and hose 2
  with the dust valve.
• If necessary, remove the hose 1.
• Loosen the clamp 2.
• Disconnect the hose 1.
• Remove the dust valve from the T-piece.
• Figure 178.

G
D
E C B
C
F
A

• Dust valve
• T-piece
• Clamp 1 (x2)
• Hose 1
• Clamp 2
• Hose 2
• Air filter
• Clean the dust valve and the T-piece.
• Make sure that the dust valve and the T-piece are
  not damaged. If necessary, replace them.

9813/6100-4
15 - 48
20
15 - Engine 27 - Crankcase Ventilation Filter 00
- General

• Remove and Install
• Remove
• Make the machine safe. Refer to (PIL 01-03).
• 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.
• Open the engine compartment access cover. Refer
  to (PIL 06-06).
• Remove the oil filler cap.
• Remove the capscrews.
• Remove the CCV (Crankcase Ventilation) filter
  cover.
• Remove the CCV filter from the rocker cover.
• Do not disturb the CCV filter gasket located on
  the rocker cover.
• If damaged, remove and discard the gasket.
• Figure 179.

B
C
E
D
A

• A CCV filter B Capscrews C Oil filler cap D
  Gasket
• E Rocker cover
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the capscrews to the correct torque
  value.
• Table 71. Torque Values

Item Nm
B 7
15 - 56
9813/6100-4
15 - 56
21
15 - Engine 63 - Mount 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-59 Remove and Install
....................................... 15-60
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.
9813/6100-4
15 - 59
22
15 - Engine 63 - Mount 00 - General
Remove and Install
Consumables

1. 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.
2. Remove the engine front mount from the machine
   as follows

Description Part No. Size
Waxoyl 4004/0501A 0.4L
Waxoyl 4004/0502 5L
Waxoyl 4004/0505 200L
Remove 1. Make the machine safe. Refer to (PIL
01-03). Figure 180.
D C F B
A
E

• A Engine
• C Washer 1 (x8)
• E Locknut 1 (x4)
• Remove the bolt 1 (x4), locknut 1 (x4) and
  washers 1 (x8).
• Remove the spacers (x2).

B Bush (x4) D Bolt 1 (x4) F Front mount 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
9813/6100-4
15 - 59
23
15 - Engine 63 - Mount 00 - General
Figure 181.
K
U
L
G
S
R
J
H Q
P
N
T M

• G Rear mount plate J Locking plate (x2) L
  Washer 2 (x2)
• N Bolt 3 (x4)
• Q Locknut 3 (x8)
• S Overload washer
• U Boss
• Remove the setscrews (x8) and locknut 3 (x8).
• Lift the engine and transmission assembly away
  from the machine. Refer to (PIL 15-00).
• Use a suitable stand to support the engine and
  transmission assembly.
• Remove the bolt 2 (x2), locknut 2 (x2) and
  washers 2 (x2).

H Resilient mount K Bolt 2 (x2) M Locknut 2 (x2)
P Washer 3 (x4) R Setscrew (x8) T Rebound washer

1. Remove the rebound washer, resilient mount and
   overload washer.
2. Remove the bolt 3 (x4), washers 3 (x4) and
   locking plate (x2).
3. Collect the boss (x4).
4. Remove the rear mount plate from the
   transmission.

9813/6100-4
15 - 59
24
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15 - Engine 63 - Mount 00 - General

• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Apply locking fluid to the bolt 2 before
  installation. Consumable Waxoyl
• Tighten the nuts to the correct torque value.
• Apply Waxoyl to the bolt 3 after you tighten it.
• Table 72. Torque Values

Item Nm
D 43
K 360
N 520
R 44
15 - 62
9813/6100-4
15 - 62
26
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com