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.

SERVICE MANUAL 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.

LOADER
432ZX PLUS 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
EN - 9823/0650 - ISSUE 1 - 05/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products

Copyright 2018 © JCB SERVICE

78 - After Sales
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.

[Link]
Notes:

9823/0650-1

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 Spine Cards

SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2

432ZX PLUS 432ZX PLUS

EN 9823/0650 EN 9823/0650

SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4

432ZX PLUS 432ZX PLUS

EN 9823/0650 EN 9823/0650

9823/0650-1

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Notes:

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 01 - Machine
Contents Page No.

Acronyms Glossary .................................................................................................................................... 01-2

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
01-06-09 Left-Hand Side, Right-Hand Side ................................................................................... 01-19
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

9823/0650-1
2018-04-05

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Acronyms Glossary

PIL Parts Identification List

9823/0650-1
2018-04-05

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 01 - Machine
03 - Safety

03 - Safety

Contents Page No.

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 - 1 9823/0650-1 01 - 1

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01 - 2 9823/0650-1 01 - 2

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 01 - Machine
03 - Safety
03 - Safety - Yours and Others

03 - Safety - Yours and Others

Introduction

All machinery can be hazardous. When a machine

is correctly operated and maintained, it is a safe
machine to work with. When it is carelessly operated
or poorly maintained it can become a danger to you
(the operator) and others.

In this manual and on the machine you will find

warning messages, you must read and understand
them. They inform you of potential 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 you are working on or with the
machine you must be thinking of what hazards there
might be and how to avoid them.

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.

If you are not sure of anything, about the machine or

the work, ask someone who knows. Do not assume
anything.

Remember:

• Be careful
• Be alert
• Be safe.

01 - 3 9823/0650-1 01 - 3

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 01 - Machine
03 - Safety
06 - Safety Warnings

06 - Safety Warnings

Introduction

In this manual there are safety notices. Each notice

starts with a signal word. The signal word meanings
are given below.

The signal word 'DANGER' indicates a hazardous

situation which, if not avoided, will result in death or
serious injury.

The signal word 'WARNING' indicates a hazardous

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 signal word 'Notice' indicates a hazardous

situation which, if not avoided, could result in
machine damage.

The safety alert system symbol (shown) also helps

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.

Figure 1. The safety alert system symbol

01 - 4 9823/0650-1 01 - 4

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 01 - Machine
03 - Safety
09 - General Safety

09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware 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 Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.

01 - 5 9823/0650-1 01 - 5
 01 - Machine
03 - Safety
12 - Maintenance Safety

12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6 m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.

01 - 6 9823/0650-1 01 - 6
 01 - Machine
03 - Safety
12 - Maintenance Safety

Working Under the Machine

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. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300 °C
require no special safety precautions. If evidence
of decomposition (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 than 300 °C (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn: Thoroughly wash
contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.

01 - 7 9823/0650-1 01 - 7
 01 - Machine
03 - Safety
18 - Operating Safety

18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.

01 - 8 9823/0650-1 01 - 8
 01 - Machine
03 - Safety
18 - Operating Safety

Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible.
and repair before resuming work.
Roll Over Protection
Hot Components
If the machine starts to roll over, you can be crushed
Touching hot surfaces can burn skin. The engine and if you try to leave the cab. If the machine starts to roll
machine components will be hot after the unit has over, do not try and jump from the cab. Stay in the
been running. Allow the engine and components to cab, with your seat belt fastened.
cool before servicing the unit.
Confined Areas
Travelling at High Speeds
Pay extra attention to proximity hazards when
Travelling at high speeds can cause accidents. operating in confined areas. Proximity hazards
Always travel at a safe speed to suit working include buildings, traffic and bystanders.
conditions.
Safe Working Loads
Hillsides
Overloading the machine can damage it and make it
Operating the machine on hillsides can be unstable. Study the specifications in the Operator's
dangerous if the correct precautions are not taken. Manual before using the machine.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep Lightning
all attachments low to the ground. If you are inside the machine during a lightning storm
Visibility stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
Accidents can be caused by working in poor visibility. storm stay away from the machine until the storm
Use your lights to improve visibility. Keep the road has passed. Do not attempt to mount or enter the
lights, windows, mirrors and cameras clean (when machine.
fitted).
If the machine is struck by lightning do not use the
Do not operate the machine if you cannot see clearly. machine until it has been checked for damage and
Modification of the machine's configuration by the malfunction by trained personnel.
user (e.g. the fitting of large and non-approved
attachments) may result in a restriction of the
machine visibility.

01 - 9 9823/0650-1 01 - 9
 01 - Machine
03 - Safety
21 - Worksite Safety

21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas 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 running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.

01 - 10 9823/0650-1 01 - 10
 01 - Machine
03 - Safety
24 - Risk Assessment

24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and
into account.
experience of the operator. Do not put your life or the
• How steep are any slopes, up/down/across?
lives of others at risk.
A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and
• How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested?
the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator.
the load is bulky.
• Is supervision needed? Is the supervisor
• Is it raining or is rain likely? The ground that
sufficiently trained and experienced?
was solid and smooth when dry will become
• As well as the machine operator, are any
uneven and slippery when wet, and it will not
assistants or lookouts needed?
give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and 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 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?

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 01 - Machine
03 - Safety
27 - Maintenance Positions

27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 Make the machine safe before you start a
Health and Safety .......................................... 01-14 maintenance procedure. You can complete most
of the maintenance procedures with the lift arm
lowered. Unless a maintenance procedure instructs
you differently, you must lower the lift arm.

Lift Arm Lowered

Figure 2.
A

A Lift arm lowered

1. If necessary, empty the shovel. 6. Remove the battery isolation key.

2. Make sure that the machine is parked correctly in 7. Install the articulation lock.
the straight-ahead position on solid, level ground.
8. Operate the controls to release the residual
3. Lower the lift arm and put the attachment flat on pressure.
the ground.
9. If you are working on an area that you cannot
4. Stop the engine and remove the ignition key. reach when standing on the ground, you must
use a suitable, safe work platform.
5. Put chocks on both sides of all wheels.

Lift Arm Raised

Figure 3.
B

B Lift arm raised

01 - 12 9823/0650-1 01 - 12
 01 - Machine
03 - Safety
27 - Maintenance Positions

If you must raise the lift arm to get access to 6. Put chocks on both sides of all wheels.
perform non-routine maintenance procedures, lift
arm support devices must be used. 7. Install the articulation lock.

Lift arm support devices are supplied with a machine 8. Remove the maintenance struts from their
as an option and your machine may not be equipped stowage position.
with them. Do not attempt to carry out maintenance 9. Put a maintenance strut in position around the
operations beneath a raised lift arm unless you use ram on one side of the machine and lock the strut
the correct lift arm support devices. in position with the strap.
Install the Maintenance Struts (If supplied) 10. Put the other maintenance strut in position
around the ram on the other side of the machine
1. If necessary, empty the shovel. and lock the strut in position with the strap
2. Make sure that the machine is parked correctly in 11. Start the engine.
the straight ahead position on solid, level ground.
12. Slowly lower the lift arm onto the maintenance
3. Raise the lift arm sufficiently to install the struts. Stop the movement immediately when the
maintenance struts. maintenance struts support the weight of the lift
arm.
4. Run the engine at idle for a few minutes to let the
turbocharger cool. 13. Stop the engine and remove the ignition key.
Duration: 2 –3 min
14. Remove the battery isolation key.
5. Stop the engine and remove the ignition key.

Figure 4.

A A
B
B

A Strut (one of two) B Strap

C Strap D Strut (two of two)

Stow the Maintenance Struts 8. Put the maintenance struts in their stowage
position.
1. Engage the park brake. Make sure that the
transmission is in neutral. 9. Remove the articulation lock.

2. Install the battery isolation key. 10. Remove the chocks on both sides of all wheels.

3. Start the engine.

4. Raise the lift arm sufficiently to remove the weight
from the maintenance struts.
5. Stop the engine.
6. Remove the strap from one of the maintenance
struts and remove the strut.
7. Remove the strap from the other maintenance
strut and remove the strut.

01 - 13 9823/0650-1 01 - 13
 01 - Machine
03 - Safety
27 - Maintenance Positions

Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
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 (by means
of the battery isolator if installed) 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 9823/0650-1 01 - 14
 01 - Machine
06 - About this Manual

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 ................................................................................... 01-19

01 - 15 9823/0650-1 01 - 15
Notes:

01 - 16 9823/0650-1 01 - 16
 01 - Machine
06 - About this Manual
03 - Model and Serial Number

03 - Model and Serial Number

Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
432ZX PLUS 2609501 2609800
2693541

01 - 17 9823/0650-1 01 - 17
 01 - Machine
06 - About this Manual
06 - Using the 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 PIL 30-00-50 Schematic Circuit
Electrical System PIL 33-03-03 Battery - Isolator Switch
PIL 33-09-00 Power Distribution (including fuses
and relays)
PIL 33-00-50 Schematic Circuit
Electronic Diagnostic PIL 33-57-00 Electronic Diagnostic (including
Servicemaster)

Machine Variants • Use the applicable Servicemaster diagnostics

tools.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified, use
Information in this manual can help you diagnose the standard torque tightening values. For the torque
machine faults. setting to be effective, do the following before you
install the fixings. Refer to PIL 72-00-00.
Before attempting to diagnose possible faults check
the following. • Make sure that all the applicable component
assemblies are correct.
• Make sure that the operator understands the • Make sure that the applicable fixings are to the
machine controls, functions and use. Refer to correct specification. If necessary discard the
the applicable Operator Manual. original fixings and replace them with new ones.
• Check that the maintenance record complies The relevant procedures indicate when this is
with the applicable schedule for the operating necessary.
environment. • Make sure that the applicable fixings and
• Check that the fluids in use comply with the threaded holes are free from contamination.
standards specified. This includes dirt, debris, old sealants and
• Make sure that the machine electronic set-up compounds, fluids and lubricants.
is applicable. Use the applicable Servicemaster
vehicle set-up tool.

01 - 18 9823/0650-1 01 - 18
 01 - Machine
06 - About this Manual
09 - Left-Hand Side, Right-Hand Side

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 machine.

Figure 5.
B

A
A Left
B Right

01 - 19 9823/0650-1 01 - 19
 01 - Machine
09 - Description

09 - Description

Contents Page No.

01-09-12 Main Component Locations ........................................................................................... 01-21

01-09-15 Service Point Locations ................................................................................................. 01-22

01 - 20 9823/0650-1 01 - 20
 01 - Machine
09 - Description
12 - Main Component Locations

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
G Bucket J Tool box (Behind the seat)
L Loader arm M Ram

01 - 21 9823/0650-1 01 - 21
 01 - Machine
09 - Description
15 - Service Point Locations

15 - Service Point Locations

Introduction

Figure 7.
B A G
F

D C

A Coolant filler cap B Coolant expansion tank

C Fuel filler cap D Engine oil filter
E Transmission dipstick F Exhaust silencer
G Intake air filter

01 - 22 9823/0650-1 01 - 22
 01 - Machine
09 - Description
15 - Service Point Locations

Figure 8. Figure 9.

A Battery
B Battery Isolator

A Engine oil drain plug

Figure 10.

A Hydraulic tank filler B Fuel filter

C Water separator D Hydraulic filter

01 - 23 9823/0650-1 01 - 23
 01 - Machine
09 - Description
15 - Service Point Locations

Figure 11. Figure 13.

A A
B
A Radiator
D Figure 14.
C
A
A Access panel
B Fuel tank
C Drain plug
D Strainer
Figure 12.

A Hydraulic oil level gauge

Figure 15.

C
A

B
D
A Access panel
B Hydraulic tank
C Drain plug
D Strainer

A Clip
B Recirculation filter

01 - 24 9823/0650-1 01 - 24
 01 - Machine
33 - Cleaning

33 - Cleaning

Contents Page No.

01-33-00 General ........................................................................................................................... 01-27

01 - 25 9823/0650-1 01 - 25
Notes:

01 - 26 9823/0650-1 01 - 26
 01 - Machine
33 - Cleaning
00 - General

00 - General Introduction
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-27 or other chemicals, you must adhere to
Preparation .................................................... 01-28 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
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 that require

components to be removed:

• The cleaning must be done 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 the surrounding product must
be cleaned.
• When cleaning is complete, move the product
away from the wash area or alternatively,
remove the material washed from the product.

When you remove components, be aware of

exposure to dirt and debris. Cover any open ports
and remove the deposits before proceeding.

Detergents
Do not use a full strength detergent. Always
dilute the detergents as per the manufacturer's
recommendations, or damage to the paint finish can
occur.

Always obey the local regulations regarding the

disposal of debris created from cleaning the product.

Pressure Washing and Steam Cleaning

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.

01 - 27 9823/0650-1 01 - 27
 01 - Machine
33 - Cleaning
00 - General

Notice: The engine and other components could Preparation

be damaged by high pressure washing systems.
Special precautions must be taken if the machine
is to be washed using a high pressure system. 1. Make the machine safe. Stop the machine and
let it cool for at least one hour. Do not try to clean
Make sure that the alternator, starter motor and any part of the machine while it is running.
any other electrical components are shielded
and not directly cleaned by the high pressure 2. Make sure that all of the electrical connectors are
cleaning system. Do not aim the water jet directly correctly coupled.
at bearings, oil seals or the engine air induction
system. 3. If the connectors are open, attach the correct
caps or seal with waterproof tape.
Use a low pressure water jet and brush to remove
dried mud or dirt.

Use a pressure washer to remove soft dirt and oil.

The product must always be greased (if appropriate)

after pressure washing or steam cleaning.

01 - 28 9823/0650-1 01 - 28
 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
03-30-00 General ........................................................................................................................... 03-11

9823/0650-1
2018-04-03
Notes:

9823/0650-1
2018-04-03
 03 - Attachments, Couplings and Load Handling
00 - Attachments

00 - Attachments

Contents Page No.

03-00-00 General ............................................................................................................................. 03-3

03 - 1 9823/0650-1 03 - 1
Notes:

03 - 2 9823/0650-1 03 - 2
 03 - Attachments, Couplings and Load Handling
00 - Attachments
00 - General

00 - General Introduction
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.

Some attachments are supplied complete with

instructions on safety, installing and removing,
operation and maintenance. Read and fully
understand the information before fitting, using and
servicing the attachment. If there is anything you do
not understand, ask your JCB Distributor.

Before using any attachment, read Working With

The Machine in the Operator Manual and consider
how the attachment is going to affect operational
safety. With the attachment installed, there may
be changes in the machine's centre of gravity or
overall dimensions. This could have an effect on, for
example, machine stability, the gradients 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 manufactured

specifically to suit the machine's hydraulic system,
mounting arrangements and safe load requirements.
Attachments which are not designed for use with
this machine may cause damage and create safety
hazards for which JCB cannot be held responsible.
In addition the machine's warranty and any other
legislative compliance may be affected by the use of
non JCB approved attachments.

If your machine needs the hydraulic system adapting

to facilitate the use of auxiliary attachments, you
must consult your distributor. Only suitably qualified
personnel must reroute hydraulic hoses.

All optional attachments will have limits on their

operation. i.e. lifting capacity, speeds, hydraulic flow
rates, etc. Always check in the literature supplied
with the attachment or in the Specification section of
this manual. Some specification limits may also be
displayed on the attachments Data/Rating Plate.

Important: Do not operate or work with attachments

until the machine hydraulic oil has reached its normal
working temperature.

03 - 3 9823/0650-1 03 - 3
 03 - Attachments, Couplings and Load Handling
00 - Attachments
00 - General

Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator'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! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.

03 - 4 9823/0650-1 03 - 4
 03 - Attachments, Couplings and Load Handling
09 - Lift Arm Quickhitch

09 - Lift Arm Quickhitch

Contents Page No.

03-09-00 General ............................................................................................................................. 03-7

03-09-06 Hydraulic Quickhitch ........................................................................................................ 03-8

03 - 5 9823/0650-1 03 - 5
Notes:

03 - 6 9823/0650-1 03 - 6
 03 - Attachments, Couplings and Load Handling
09 - Lift Arm Quickhitch
00 - General

00 - General

Introduction

Quickhitches are used on machines to allow the rapid

change of 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 on a machine
they become a part of the overall machine system.
They are usually mounted on the machine by means
of pins that would otherwise be the mountings for the
shovel or attachment.

03 - 7 9823/0650-1 03 - 7
 03 - Attachments, Couplings and Load Handling
09 - Lift Arm Quickhitch
06 - Hydraulic Quickhitch

06 - Hydraulic Quickhitch Figure 16.

Introduction
WARNING If two people are doing this job make
sure that the person working the controls is a
competent operator. If the wrong control lever is
moved, or if the controls are moved violently, the
other person could be killed or injured.
WARNING Do not retract the locking pins when
the lift arm is raised, the shovel could fall and kill
or seriously injure someone. Retract the locking
pins only after the attachment has been placed on
the ground.
B
Keep other people clear of the area while you engage A
the attachment. If a second person is to be involved
in this procedure, make sure that they keep clear of A Locking pins
the machine and attachment until signalled by you to B Indicators
proceed.

For more information on the servo-control lever and Lubricate

the auxiliary controls
Remove the attachments before you grease the
A Quickhitch isolator valve is installed on all locking pins. Total of 2 grease points. Refer to Figure
machines. This valve can be used to hydraulically 16.
operate the locking pins to lock an attachment to the
Quickhitch. The valve is operated by the Quickhitch When working in difficult conditions, grease and
isolator switch in the cab. operate the locking-pins every 10 hours.

When the Quickhitch isolator switch is operated

at the same time as the auxiliary buttons/lever,
hydraulic pressure is diverted to the locking pins.

• When the locking pins are fully out, they are

disengaged.
• When the locking pins are partially out, they are
partially engaged.
• When the locking pins are fully in, they are fully
engaged.

The red indicators show the position of the pins, the

main pins are fully engaged when the red indicators
can't bee seen anymore.

03 - 8 9823/0650-1 03 - 8
 03 - Attachments, Couplings and Load Handling
30 - Shovel

30 - Shovel

Contents Page No.

03-30-00 General ........................................................................................................................... 03-11

03 - 9 9823/0650-1 03 - 9
Notes:

03 - 10 9823/0650-1 03 - 10
 03 - Attachments, Couplings and Load Handling
30 - Shovel
00 - General

00 - General Introduction
Introduction .................................................... 03-11 A shovel can be installed on many different types of
Health and Safety .......................................... 03-12 earthmoving machines. The shovel can be directly
Remove and Install ....................................... 03-13 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 loose material

from the ground, such as dirt, sand or gravel, and
move it from one place to another without pushing
the material across the ground. It is commonly used
to move stockpiled material from ground level and
deposited into a dump truck or into an open trench
excavation.

03 - 11 9823/0650-1 03 - 11
 03 - Attachments, Couplings and Load Handling
30 - Shovel
00 - General

Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.

03 - 12 9823/0650-1 03 - 12
 03 - Attachments, Couplings and Load Handling
30 - Shovel
00 - General

Remove and Install

Consumables 3. Remove the bolt 1 and washer from the pivot pin
Description Part No. Size that attaches the shovel and Z bar linkage.
Special HP Grease 4003/2020 0.5 kg 3.1. Use a suitable hammer and drift to remove
4003/2017 0.4 kg the pivot pin.
4003/2006 12.5 kg
4. Remove the bolt 2 (x2) and washer (x2) from the
4003/2005 50 kg
pivot pin (x2) that attaches the shovel and loader
arm.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting 4.1. Use a suitable hammer and drift to remove
equipment. You must identify the weight of the item to the pivot pin.
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting 5. Carefully lift and remove the shovel away from
equipment is in good condition and complies with all the machine.
local regulations. 6. Inspect the condition of the bushes and seals at
the pivot pin joints.
Remove
7. Replace worn or damaged bushes and/or seals.
1. Make the machine safe with the lift arm lowered. Use a press to remove and install the bushes and
Refer to: PIL 01-03-27. seals.

2. Remove the bolt (x2), washer (x2) from the pivot

pin that attaches the shovel and the shovel lever.

03 - 13 9823/0650-1 03 - 13
 03 - Attachments, Couplings and Load Handling
30 - Shovel
00 - General

Figure 17.
G
B
H
F
D
J
G
E

A
C
B

F
H C

J G

A Shovel B Z bar linkage

C Loader arm D Bolt 1
E Washer F Pivot pin
G Seal H Bearing
J Shim K Bolt 2

03 - 14 9823/0650-1 03 - 14
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