jcb 427, Service Manual

Page 1: ...al 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 Operat...

Page 2: ...9813 6100 4 Notes Find manuals at https best manuals com...

Page 3: ...MANUAL Volume 1 427 435S 437 EN 9813 6100 SERVICE MANUAL Volume 2 427 435S 437 EN 9813 6100 SERVICE MANUAL Volume 3 427 435S 437 EN 9813 6100 SERVICE MANUAL Volume 4 427 435S 437 EN 9813 6100 Find ma...

Page 4: ...Notes 9813 6100 4 Find manuals at https best manuals com...

Page 5: ...ety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 1...

Page 6: ...9813 6100 4 2017 02 07 Acronyms Glossary FOPS Falling Object Protective Structure PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com...

Page 7: ...y Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessme...

Page 8: ...Notes 01 2 9813 6100 4 01 2 Find manuals at https best manuals com...

Page 9: ...hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time...

Page 10: ...ion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word N...

Page 11: ...ware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile...

Page 12: ...ulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure t...

Page 13: ...composition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater tha...

Page 14: ...y kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel dro...

Page 15: ...Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...ecessary empty the shovel 2 Make sure that the machine is parked correctly in the straight ahead position on solid level ground 3 Apply the park brake 4 Lower the lift arm and put the attachment flat...

Page 19: ...he articulation lock Refer to PIL 06 27 10 Remove the maintenance struts from the tool box 11 Install the maintenance strut in correct position around the ram 12 Make sure that the maintenance strut i...

Page 20: ...ny maintenance make sure the machine is safe it must be correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not usi...

Page 21: ...01 Machine 06 About this Manual 01 15 9813 6100 4 01 15 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18...

Page 22: ...Notes 01 16 9813 6100 4 01 16...

Page 23: ...al 03 Model and Serial Number 01 17 9813 6100 4 01 17 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 427 2311...

Page 24: ...Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls...

Page 25: ...01 Machine 09 Description 01 19 9813 6100 4 01 19 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22...

Page 26: ...Notes 01 20 9813 6100 4 01 20...

Page 27: ...n Component Locations Introduction Figure 5 A D B C G H J K L E F A ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure cab B Shovel ram C Loader arms D Shovel E Engine Engine...

Page 28: ...e Point Locations 01 22 9813 6100 4 01 22 15 Service Point Locations Introduction Figure 6 A B C D E G F A Radiator B Coolant expansion tank C Air filter D Engine oil filler cap E Engine oil dipstick...

Page 29: ...01 Machine 09 Description 15 Service Point Locations 01 23 9813 6100 4 01 23 Figure 7 A A Engine oil drain Figure 8 A B A Battery B Battery isolator...

Page 30: ...01 Machine 09 Description 15 Service Point Locations 01 24 9813 6100 4 01 24 Figure 9 A A Transmission filler point Figure 10 A A Transmission gauge...

Page 31: ...01 Machine 09 Description 15 Service Point Locations 01 25 9813 6100 4 01 25 Figure 11 A A Hydraulic level gauge...

Page 32: ...01 Machine 33 Cleaning 01 26 9813 6100 4 01 26 33 Cleaning Contents Page No 01 33 00 General 01 27...

Page 33: ...ender the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures...

Page 34: ...aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oi...

Page 35: ...lings and Load Handling Contents Page No 03 00 Attachments 03 00 00 General 03 3 03 09 Lift Arm Quickhitch 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 03 12 Hitch 03 12 12 Mechanical Tow...

Page 36: ...Notes 9813 6100 4 2017 02 08...

Page 37: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 6100 4 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 38: ...Notes 03 2 9813 6100 4 03 2...

Page 39: ...ients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactu...

Page 40: ...r s Manual do not install it use it or remove it until you have obtained read and understood the pertinent information Install attachments only on the machines for which they were designed WARNING Loa...

Page 41: ...03 Attachments Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9813 6100 4 03 5 09 Lift Arm Quickhitch Contents Page No 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8...

Page 42: ...Notes 03 6 9813 6100 4 03 6...

Page 43: ...buckets shovels and other attachments on the machine Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations but when installed o...

Page 44: ...e the attachment If a second person is to be involved in this procedure make sure that they keep clear of the machine and attachment until signalled by you to proceed For more information on the servo...

Page 45: ...onnect and Connect Disengage the Attachment Figure 13 A A Locking pins 1 Park the machine on solid level ground 2 Engage the park brake and put the transmission in neutral 2 1 If necessary disconnect...

Page 46: ...er control option Move the lever forward and tilt the Quickhitch forward and lower the lift arm 7 When the pivot shaft has disengaged from the hooks reverse the machine clear Figure 16 A B A Hooks B P...

Page 47: ...dump C Auxiliary 1 D Auxiliary 2 option E Differential lock F Horn G Transmission kickdown switch H Forward reverse switch 7 Push and hold the quickhitch isolator switch 8 Engage the locking pins in...

Page 48: ...ts Couplings and Load Handling 09 Lift Arm Quickhitch 06 Hydraulic Quickhitch 03 12 9813 6100 4 03 12 Lubricate There are two greasing points for the lubrication of the quickhitch Refer to Figure 21 F...

Page 49: ...er to PIL 01 03 2 Install the articulation strut Refer to PIL 06 27 3 Isolate the battery from the electrical circuit Refer to PIL 33 03 4 Use suitable lifting equipment to support the quickhitch 5 Di...

Page 50: ...ings and Load Handling 09 Lift Arm Quickhitch 06 Hydraulic Quickhitch 03 14 9813 6100 4 03 14 1 Use a press to install the new bush and then replace the seal Figure 25 H H H Shims 2 Install the spacer...

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