PDF Service Manual JCB WLS 432ZX Wheeled Loader - 3 MB
This is the complete factory service manual for the JCB WLS 432ZX Wheeled Loader.
It contains all the information you need to perform everything from basic maintenance to complex overhauls.
The manual includes detailed specifications, troubleshooting flowcharts, and step-by-step repair procedures.
A must-have for any mechanic or owner responsible for the upkeep of a JCB 432ZX.
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--- Page 1 ---
Service Manual
WLS 432ZX
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Publication No.
550/43477/1
World Class
Customer Support
Copyright © 2004 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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
--- Page 3 ---
Section 1 - General Information
General Information
Colour Codes
Fig 4.
Service Tools
Section B - Body and Framework
826/01179 M6 x 16mm Rivet Nut
826/01106 M6 x 19mm Rivet Nut
826/01177 M8 x 18mm Rivet Nut
826/01176 M10 x 23mm Rivet Nut
826/01333 M10 x 26mm Rivet Nut
Installation Tool Available from : Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
The Willenhall
Willenhall
West Midlands, WV13 2JW
Folding Stand for Holding Glass Essential for preparing new glass prior to installation. JCB
part number - 892/00843 K Fig 5. ( T 1-8)
1-7 550/43477/1 1-7
--- Page 4 ---
Section 2 - Care and Safety
Notes:
2-0 550/43477/1 2-0
--- Page 5 ---
Section 2 - Care and Safety
Care & Safety
Safety Notices
!MCAUTION !MWARNING
'O' rings, Seals and Gaskets Certain seals and gaskets (e.g. crankshaft oil seal) on
Badly fitted, damaged or rotted 'O' rings, seals and JCB machines contain fluoroelastomeric materials
gaskets can cause leakages and possible accidents. such as Viton, Fluorel and Technoflon.
Renew whenever disturbed unless otherwise Fluoroelastomeric materials subjected to high
instructed. Do not use Triochloroethane or paint temperatures can produce highly corrosive
thinners near 'O' rings and seals. hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
INT-3-2-12
New fluoroelastomeric components at ambient
!MWARNING temperature require no special safety precautions.
Hydraulic Hoses Used fluoroelastomeric components whose
Damaged hoses can cause fatal accidents. Inspect the temperatures have not exceeded 300°C (572°F) require
hoses regularly for: no special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to the
– Damaged hose ends next paragraph for safety instructions DO NOT TOUCH
– Chafed outer covers COMPONENT OR SURROUNDING AREA.
– Ballooned outer covers Used fluoroelastomeric components subjected to
– Kinked or crushed hoses temperatures greater than 300°C (572°F) (e.g. engine
– Embedded armouring in outer covers fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
– Displaced end fittings.
special safety glasses are worn:
INT-3-3-2
1 Thoroughly wash contaminated area with 10%
!MCAUTION calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
Waxoyl contains turpentine substitute which is burnt remains.
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep 2 Thoroughly wash contaminated area with
flames away during the drying period. detergent and water.
Do not weld near the affected area during the drying 3 Contain all removed material, gloves etc. used in
period. Take the same precautions as for oil to keep this operation in sealed plastic bags and dispose
Waxoyl off your skin. Do not breathe the fumes. Apply of in accordance with Local Authority
in a well-ventilated area. Regulations.
5-3-1-9
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
!MWARNING INT-3-3-5_3
Working Under the Machine
Make the machine safe before getting beneath it. !MWARNING
Ensure that any fitments on the machine are secure; Protect your eyes when grinding metal. Wear safety
engage the park brake, remove the starter key, glasses or goggles. Remove or protect any
disconnect the battery. combustible materials from the area which could be
INT-3-3-8_2 ignited by sparks.
GEN-1-12
2-9 550/43477/1 2-9
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Section 3 - Maintenance
Routine Maintenance
Service Schedules
TRANSMISSION AND AXLES - Check z
Clutch Pack Pressures - Check z
Clutch Disconnect/Dump Button - Check
Clutch Pack Calibration - Check z
Speed Change and Selection - Check z
Forward/Reverse Selection/Operation - Check z
Neutral Start Operation - Check z z
Reverse Alarm (if fitted) - Check z
Oil Cooler and Pipework - Check z
Table 7.
Functional Test Operation 10 Hr 100 250 As and 500 1000 2000
Hr Hr When Hr Hr Hr
HYDRAULICS
MRV Pressure - Check and z
Adjust
Steer Circuit MRV Pressure - Check and z
Adjust
ARV Pressure - Check and
Adjust
Operation of All Services - Check z
Hoses for Damage and Leaks - Check
Pipework for Damage and Leaks - Check
Piston Rods and Gland Seals - Check
Table 8.
Functional Test Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
ELECTRICS
Starter Motor - Check z
Alternator - Check z
Gauges and Warning Lights - Check z
Proximity Sensor Function - Check z
Cab Switches - Check z
Wiper Motors - Check z
Heater - Check
Other (give details) - Check
CAB
Glazing for Correct Fit - Check z
3-4 550/43477/1 3-4
--- Page 7 ---
Section 3 - Maintenance
Routine Maintenance
Engine Oil and Filter
Engine Oil and Filter
Checking the Oil Level Changing the Oil and Filter
!MCAUTION !MWARNING
Hot oil and engine components can burn you. Make Make the machine safe before getting beneath it.
sure the engine is cool before doing this job. Lower the tipper body to the fully lowered position;
2-3-3-2 engage the park brake; remove the starter key,
disconnect the battery.
1 Park the machine on level ground and lower the 0197
attachments to the ground.
2 Stop the engine. Put the transmission in neutral and
!MCAUTION
remove the starter key. Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
3 Open the right side engine cover. 2-3-3-2
4 Check that the oil level is between the two marks on 1 Park the machine on level ground and lower the
the dipstick A K Fig 12. ( T 3-14). attachments to the ground.
5 If necessary, add the recommended oil through the 2 Stop the engine. Put the transmission in neutral and
filler point B. remove the starter key.
6 Make sure the filler cap and the dipstick are secure. 3 Open the left side engine cover.
Close and lock the engine cover.
4 Place a suitable container beneath the drain plug (to
catch the oil).K Fig 13. ( T 3-15)
5 Unscrew the drain plug A .
6 Drain the sump oil.
Fig 12.
3 - 14 550/43477/1 3 - 14
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Section B
Body and Framework
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Publication No.
550/43477/1
World Class
Customer Support
Copyright © 2004 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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
--- Page 9 ---
Section B - Body and Framework
Body & Framework
Cab
Cooling Pack
Introduction
This cooling pack is a combination pack. It provides all the
necessary cooling activities for the machine’s components
with the exception of the Air Conditioning. (It should be
noted that whilst most machines are fitted with air
conditioning, it is an optional fitment. Its fitment or not
makes no difference to the main cooling pack’s function.)
When viewed from the the engine side A, the individual
sections of the cooling pack are: 1 Hydraulic oil cooling 2
Engine Coolant Radiator 3. K Fig 6. ( T B-8)Transmission
Oil Cooling.
The cooling pack sections are held together by top and
bottom holding plates. By removing the section securing
bolts, it is possible to remove and replace a single section.
It is intended that to replace a single section the complete
pack will need to be removed from the machine.
Key Fig 6.
7 Coolant drain plug.
8 The cooling packs lower mounting points. Removal and Replacement
Removal
The cooling pack is a combination unit that cools water, air,
transmission and hydraulic oils. Before attempting to work
onthe cooling pack unit, all appropriate safety measures
must be taken.
1 Park the machine on firm level ground and lower the
loader arms. Engage the parking brake. Put the
transmission in neutral and chock both sides of all
four wheels. Stop the engine and let it cool down.
Operate the hydraulic control levers to release
pressure trapped in the hoses then remove the
hydraulic tank filler cap. Refit the cap once any
residual pressure has been released.
B-8 550/43477/1 B-8
--- Page 10 ---
Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 5. Energy Transmissions and Conditioning
Working line, return or feed Reservoir - return line above
fluid level
Pilot control
Reservoir - return line below
Drain lines fluid level
Flexible pipe
Header tank
Line junction
Pressure sealed tank
Accumulator
Crossing lines
Filter or strainer
Air bleed
Line plugged, also pressure
Water trap
test point
Line plugged with take off line Cooler - with no indication of
coolant flow
Quick release couplings -
connected
Cooler - indicating direction of
coolant flow
Quick release couplings -
disconnected
Heater
E-3 550/43477/1 E-3
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Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
Assembly end covers. PGP/PGM350 and 365 have one plug on
the outlet side of their shaft end and por/t end covers
1 Stone all machined surfaces with a medium grit
4 New plugs should be screwed in tightly. Stake the
carborundum stone K Fig 20. ( T E-13).
plug with a prick punch at both ends of the screwdrive
slot and around edges. Peen the edge of the hole 1/
32” to 1/16” with a 1-1/2” diameter steel ball. K Fig
22. ( T E-13) Note : If new plug or plugs are being
installed, coat threads with Loctite thread sealant.
Fig 20.
2 If the bushings have been removed, deburr the
bushing bores with an emery cloth. Rinse parts in a
solvent. Air blast all the parts and wipe with a clean,
lintless cloth before starting assembly K Fig
21. ( T E-13).
Fig 22.
Note: Assembly steps 5, 6, 7, & 8, apply to shaft end cover,
bearing carrier and portend cover. Any bushings removed
from the shaft end cover, portend cover or bearing carrier
should be assembled in the drive bores with the groove to
the top of unit (12 o’clock). Assemble the bushings in the
driven bores with the groove to the bottom of the unit
(6o’clock). The PGP/PGM315 does not have grooved
bushings, therefore the bushing seeams shold be placed
at the 12 and 6 o’clock positions.
5 Bushings should be pressed into the bores, one at a
time, using the special installation tool and and arbor
press. Be sure the that the grooves (or seams) are
positioned as stated in Step #5. The bushings must
be pressed into the bores flush with the casting face.
Be sure to support the castings so that they are
Fig 21. square and level K Fig 23. ( T E-14).
3 Grip shaft end cover in vise with mounting face down
Examine plug or plugs* to be sure they’re tightly in
place. Replacement is necessary only if parts are
damaged. Remove with screwdriver. * PGP/PGM315
and 330 have two plugs in both the shaft end and port
E - 13 550/43477/1 E - 13
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Section E - Hydraulics
Hydraulics
Recommended Start-Up
Fig 44.
INLET SECTION
The inlet port is at the side of the section shown with a
green colorK Fig 44. ( T E-23).
The cross-section of the main relief is also shown for
reference.
E - 23 550/43477/1 E - 23
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Section E - Hydraulics
Hydraulics
Venting the Hydraulic Pressure
Venting the Hydraulic Pressure
!MWARNING 5 Operate the loader control lever repeatedly to vent
any residual pressure.
Hydraulic Pressure (Servo Machines)
Hydraulic fluid at system pressure can injure you. 6 Turn OFF the ignition and disconnect the batteries to
Before disconnecting or connecting hydraulic hoses, ensure the machine cannot be started while the
stop the engine. When the engine has stopped, turn hydraulic system is open.
the starter switch to on. Operate the controls to
release pressure trapped in the hoses. Turn the starter Automatic Carry Control System Venting
switch to off. Make sure the engine cannot be started
while the hoses are open. Before attempting any maintenance work on the load
5-1-7-1 suspension hydraulic system, the isolating ball valve must
be OPEN.
Machines from the serial number given above are fitted
with a new generation loader control valve. A feature of this The isolating ball valve is normally CLOSED for ACCS to
new valve is that when the ignition is turned off, the servo be operative K Fig 57. ( T E-33).
control is disconnected from its pressure accumulator.
This can falsely give the impression should the control
lever be operated, that there is no residual pressure in the !MWARNING
system. To prevent the hydraulic system being opened The loader arms will fall to the ground if they are not
whilst there is still residual pressure present, the following on the ground or securely supported before the
venting procedure MUST be carried out isolating ball valve is opened. Ensure isolating ball
valve is open before attempting any maintenance work
1 Park the machine on firm level ground. Lower the on the load suspension hydraulic circuit. The isolating
attachments to the ground, apply the park brake and ball valve is closed for normal system operation.
set the transmission to neutral K Fig 56. ( T E-33). 0106
2 Switch the engine OFF.
3 Turn the ignition ON, but DO NOT start the engine.
4 Ensured the loader isolation switch in the right hand
side cab switch bank is turned ON. (The switch will be
illuminated when ON.)
Fig 56.
Fig 57.
E - 33 550/43477/1 E - 33
--- Page 15 ---
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
Replacement
Replacement is the reverse of the removal procedure,
however note the following.
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
1 Take care to secure the hydraulic hoses inside the fan
housing to prevent possible contact with the fan.
2 Top up the hydraulic fluid as necessary with the
correct grade of fluid. Refer to Section 3 - Routine
Maintenance.
Fig 65.
Uni-Directional Motor
9 Remove the four bolts B securing the fan blades to
the motor hub and remove the fan. Store the fan
carefully so as not to damage the blades. (Do not refit
General
a fan with damaged blades.)
Note: Before removing or dismantling the motor, check that
10 Lower the fan housing to the closed position and its performance is as specified in Technical Data. If the
remove the two Allen bolts A securing the fan motor performance is below that specified, the motor should be
to the spider and remove the motor K Fig renewed. Renewal of components such as gears, bearings
66. ( T E-43). and housing will not effect a permanent cure. if a motor’s
output is satisfactory but there is evidence of external
leakage, it should be dismantled for re-sealing only. Before
dismantling make sure the motor’s external body and the
work area are thoroughly cleaned and are
Dismantling, Inspection and Assembly
For motor components,.
Dismantling
Note: It is very important to work in a clean environment
when repairing hydraulic motors. Plug all ports and wash
the exterior of the motor with a proper cleaning solvent
before stripping the motors.
Fig 66. 1 Remove the port plugs and ensure all oil is drained
from the motor.
E - 43 550/43477/1 E - 43
--- Page 16 ---
Section E - Hydraulics
Hydraulics
Steering Cylinder
Steering Cylinder
Dismantling of Steering Cylinder 6 Assemble Piston Rod sub assembly into tube sub
assembly with out damaging the piston seal.
1 Place cylinder on V-block and lock Cap end cover
mounting . 7 Tighten the Head end cover.
2 Open the Head End Cover Locking and unscrew the 8 Apply thread locker wherever required as
head end cover using tool recommended in Assembly recommended in drawings.
drawing.
9 Mount cylinder and test cylinder in low idle for air
3 Take out the piston rod sub assembly. bleeding.
4 Lock Rod eye mounting with a bar.
5 Unscrew the Piston nyloc nut with help of right size
spanner.
6 Slide out the piston.
7 Take out the Head end cover by sliding on piston rod.
8 Inspect all components and seals for any damages
and replace damaged parts.
Tools
Recommend
ed
Part No Tools Size Torque
3 Hook Standard Manual
Spanner
5 Spanner 50 50-55 kgf-km
Note: Apply loctite 242/ Anabond 118 on piston rod
threads.
Assembly of Steering Cylinder
1 Clean all components of cylinder thoroughly
2 Assemble seals on Piston and Head end cover as
shown in drawing.
3 Slide head end cover on piston rod.
4 Slide Piston on Piston rod end step.
5 Screw in Nyloc Nut on piston rod to recommended
torque.
E - 53 550/43477/1 E - 53
--- Page 17 ---
Section F - Transmission
Axles