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Service Manual: Foreword
Service Manual: Foreword
LOADER
427, 435S, 437 Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
www.jcb.com
Notes:
9813/6100-4
Spine Cards
EN 9813/6100 EN 9813/6100
EN 9813/6100 EN 9813/6100
9813/6100-4
Notes:
9813/6100-4
01 - Machine
Contents Page No.
01-03 Safety
01-03-03 Safety - 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 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 Manual ........................................................................................................... 01-18
01-09 Description
01-09-12 Main Component Locations ........................................................................................... 01-21
01-09-15 Service Point Locations ................................................................................................. 01-22
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-27
9813/6100-4
2017-02-07
Acronyms Glossary
9813/6100-4
2017-02-07
01 - Machine
03 - Safety
03 - Safety
01 - 1 9813/6100-4 01 - 1
Notes:
01 - 2 9813/6100-4 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
Introduction
Do not work with the machine until you are sure that
you can control it.
Do not start any work until you are sure that you and
those around you will be safe.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9813/6100-4 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
01 - 4 9813/6100-4 01 - 4
01 - Machine
03 - Safety
09 - General Safety
01 - 5 9813/6100-4 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
01 - 6 9813/6100-4 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
01 - 7 9813/6100-4 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
01 - 8 9813/6100-4 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
01 - 9 9813/6100-4 01 - 9
01 - Machine
03 - Safety
21 - Worksite Safety
01 - 10 9813/6100-4 01 - 10
01 - Machine
03 - Safety
24 - Risk Assessment
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 will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9813/6100-4 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
01 - 12 9813/6100-4 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
Lift Arm Raised 13. Install the strap around the maintenance strut
and the ram.
Figure 3.
14. Start the engine.
15. Slowly lower the lift arm onto the maintenance
struts. Stop the movement immediately when the
maintenance struts support the weight of the lift
arm.
16. Be careful when you lower the lift arm onto the
maintenance strut. 'Feather' the control lever to
lower the lift arm slowly.
17. Stop the engine.
18. Remove the ignition key.
19. Remove the battery isolation key. Refer to (PIL
33-03).
Figure 4.
If you must raise the lift arm to get access to perform
a non-routine maintenance procedure, a lift arm
support devices must be used.
6. Stop the engine. 4. Raise the lift arm sufficiently to remove the weight
from the maintenance struts.
7. Remove the ignition key.
5. Stop the engine.
8. Put chocks on both sides of all the wheels.
6. Remove the ignition key.
9. Install the articulation lock. Refer to (PIL 06-27).
7. Remove the strap from the maintenance strut.
10. Remove the maintenance struts from the tool
box. 8. Remove the maintenance strut.
11. Install the maintenance strut in correct position 9. Start the engine.
around the ram.
10. Lower the lift arm to the ground.
12. Make sure that the maintenance strut is seated
correctly on the ram. 11. Stop the engine.
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01 - Machine
03 - Safety
27 - Maintenance Positions
12. Put the maintenance strut in the tool box. Health and Safety
13. Remove the articulation lock. WARNING Maintenance must be done only by
suitably qualified and competent persons.
14. Remove the chocks.
Before doing any 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 using electrical power. If you do not take
these precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 14 9813/6100-4 01 - 14
01 - Machine
06 - About this Manual
01 - 15 9813/6100-4 01 - 15
Notes:
01 - 16 9813/6100-4 01 - 16
01 - Machine
06 - About this Manual
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
427 2311946
435S 2356576
437 2312947
01 - 17 9813/6100-4 01 - 17
01 - Machine
06 - About this Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System 30-00-50 Schematic Circuit
Electrical System 33-03-03 Battery - Isolator Switch
33-09-00 Power Distribution (including fuses
and relays)
33-00-50 Schematic Circuit
Electronic Diagnostic 33-57 Electronic Diagnostic (including
Servicemaster)
• Ensure that the operator understands the • Make sure that all the applicable component
machine controls, functions and use. Refer to assemblies are correct.
the applicable Operator Manual. • Make sure that the applicable fixings are to the
• Check that the maintenance record complies correct specification. If necessary discard the
with the applicable schedule for the operating original fixings and replace them with new ones.
environment. Refer to PIL 78-24. The relevant procedures indicate when this is
• Check that the fluids in use comply with the necessary.
standards specified. Refer to PIL 75-00. • Make sure that the applicable fixings and
• Ensure that the machine electronic set-up is threaded holes are free from contamination.
applicable. Use the applicable Servicemaster This includes dirt, debris, old sealants and
vehicle set-up tool. Refer to PIL 33-57-03. compounds, fluids and lubricants.
01 - 18 9813/6100-4 01 - 18
01 - Machine
09 - Description
09 - Description
01 - 19 9813/6100-4 01 - 19