jcb 432ZX PLUS, Service Manual

Page 1: ...l 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 Operato...

Page 2: ...9823 0650 1 Notes Find manuals at https best manuals com...

Page 3: ...VICE MANUAL Volume 1 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 2 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 3 432ZX PLUS EN 9823 0650 SERVICE MANUAL Volume 4 432ZX PLUS EN 9823 0650 Find manual...

Page 4: ...Notes 9823 0650 1 Find manuals at https best manuals com...

Page 5: ...ting 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 17 01 06 06 Using the Ma...

Page 6: ...9823 0650 1 2018 04 05 Acronyms Glossary PIL Parts Identification List 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 9823 0650 1 01 2 Find manuals at https best manuals com...

Page 9: ...ial 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...

Page 10: ...dous situation 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 si...

Page 11: ...e 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 Ph...

Page 12: ...lic 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 th...

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: ...ee clearly 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...

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: ...2 A A Lift arm lowered 1 If necessary empty the shovel 2 Make sure that the machine is parked correctly in the straight ahead position on solid level ground 3 Lower the lift arm and put the attachmen...

Page 19: ...age position 9 Put a maintenance strut in position around the ram on one side of the machine and lock the strut in position with the strap 10 Put the other maintenance strut in position around the ram...

Page 20: ...on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery by means of the battery isolator if installed when you are not using electrical power If you...

Page 21: ...chine 06 About this Manual 01 15 9823 0650 1 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 01 06 09 Left Hand Side Right Hand Side...

Page 22: ...Notes 01 16 9823 0650 1 01 16...

Page 23: ...ual 03 Model and Serial Number 01 17 9823 0650 1 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 2609501...

Page 24: ...information is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults ch...

Page 25: ...09 Left Hand Side Right Hand Side 01 19 9823 0650 1 01 19 09 Left Hand Side Right Hand Side Introduction In this manual left and right mean your left and right when you are seated correctly in the mac...

Page 26: ...01 Machine 09 Description 01 20 9823 0650 1 01 20 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 22...

Page 27: ...21 9823 0650 1 01 21 12 Main Component Locations Introduction Figure 6 A Front work lights B Rear work lights C Exhaust stack D Rain cap air filter system Pre air cleaner E Engine cover F Rear grille...

Page 28: ...Locations 01 22 9823 0650 1 01 22 15 Service Point Locations Introduction Figure 7 D E F B A G C A Coolant filler cap B Coolant expansion tank C Fuel filler cap D Engine oil filter E Transmission dips...

Page 29: ...iption 15 Service Point Locations 01 23 9823 0650 1 01 23 Figure 8 A A Engine oil drain plug Figure 9 A B A Battery B Battery Isolator Figure 10 A Hydraulic tank filler B Fuel filter C Water separator...

Page 30: ...23 0650 1 01 24 Figure 11 B A C D A Access panel B Fuel tank C Drain plug D Strainer Figure 12 A B D C A Access panel B Hydraulic tank C Drain plug D Strainer Figure 13 A A Radiator Figure 14 A A Hydr...

Page 31: ...01 Machine 33 Cleaning 01 25 9823 0650 1 01 25 33 Cleaning Contents Page No 01 33 00 General 01 27...

Page 32: ...Notes 01 26 9823 0650 1 01 26...

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: ...3 03 Attachments Couplings 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 30 Shovel 03...

Page 36: ...Notes 9823 0650 1 2018 04 03...

Page 37: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9823 0650 1 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 38: ...Notes 03 2 9823 0650 1 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 9823 0650 1 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 9823 0650 1 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: ...d For more information on the servo control lever and the auxiliary controls A Quickhitch isolator valve is installed on all machines This valve can be used to hydraulically operate the locking pins t...

Page 45: ...03 Attachments Couplings and Load Handling 30 Shovel 03 9 9823 0650 1 03 9 30 Shovel Contents Page No 03 30 00 General 03 11...

Page 46: ...Notes 03 10 9823 0650 1 03 10...

Page 47: ...ctly mounted on to a lift arm assembly or mounted to the lift arm via a quickhitch assembly There are a vast amount and size of shovels used for numerous applications A shovel can be used to scoop up...

Page 48: ...hments Couplings and Load Handling 30 Shovel 00 General 03 12 9823 0650 1 03 12 Health and Safety CAUTION This component is heavy It must only be removed or handled using a suitable lifting method and...

Page 49: ...gulations Remove 1 Make the machine safe with the lift arm lowered Refer to PIL 01 03 27 2 Remove the bolt x2 washer x2 from the pivot pin that attaches the shovel and the shovel lever 3 Remove the bo...

Page 50: ...plings and Load Handling 30 Shovel 00 General 03 14 9823 0650 1 03 14 Figure 17 A B F H D B E G G J C F H K E G G J C A Shovel B Z bar linkage C Loader arm D Bolt 1 E Washer F Pivot pin G Seal H Beari...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...