JCB Excavator Factory Service & Work Shop Manual

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. World Class Customer Support 9803/4170-14 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual Wheeled Loading Shovel - 412S, 414S, 416S Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Section i - Front Cover i-ii i-ii 9803/4170-14 Notes:

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. World Class Customer Support 9803/4170-10 Publication No. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377 Section 1 General Information Service Manual - Wheeled Loading Shovel - 412S, 416S, 416S Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

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Page No. Contents Section 1 - General Information 1 - i 1 - i Introduction About this Publication .............................................................................. 1 - 1 Identifying your Machine Identification Plates ................................................................................. 1 - 2 Torque Settings Zinc Plated Fasteners (golden finish) ...................................................... 1 - 5 JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded) 1 - 6 JCB Standard Torque Settings for Hose Ends and Flanged Fittings (Colour Coded) ............................................................. 1 - 7 Service Tools Numerical List Section B - Body and Framework .................................... 1 - 8 Tool Detail Reference Section B - Body and Framework ........................ 1 - 9 Numerical List Section C - Electrics ...................................................... 1 - 13 Tool Detail Reference Section C - Electrics ........................................... 1 - 14 Numerical List Section E - Hydraulics ................................................... 1 - 15 Tool Detail Reference Section E- Hydraulics ......................................... 1 - 18 Numerical List Section F - Transmission ............................................... 1 - 22 Tool Detail Reference Section F - Transmission .................................... 1 - 23 Numerical List Section K - Engine ......................................................... 1 - 26 Tool Detail Reference Section K - Engine ............................................. 1 - 27 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 28

Page No. Contents Section 1 - General Information 1 - ii 1 - ii

Section 1 - General Information 1 - 1 1 - 1 9803/4170-10 Introduction About this Publication This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 General Information - includes torque settings and service tools. 2 Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machines: 412S Wheeled Loading Shovel from machine serial number 535000 414S Wheeled Loading Shovel from machine serial number 537000 416S Wheeled Loading Shovel from machine serial number 543000 The information provided in this manual for the 414S machine also applies to the 416S machine except where speciified. Smoothshift Transmission introduced from the following serial numbers: 412S Wheeled Loading Shovel from machine serial number 535500 414S Wheeled Loading Shovel from machine serial number 537300 416S Wheeled Loading Shovel from machine serial number 543100 JCB 444 Series engine added to 412S Wheeled Loading Shovel from machine serial number 1242000. A Attachments B Body & Framework...etc.

Section 1 - General Information 1 - 2 1 - 2 9803/4170-10 Identifying your Machine Identification Plates Identification Plate Your machine has an identification plate 1X mounted on the left hand side of the machine on the loader arm pillar. The serial numbers of the machine and its major units are stamped on the plate. Fig 1. Explanation of Vehicle Identification Number (VIN) 1 World Manufacturer Identification, SLP = JCB 2 Machine Model, 412S0 = 412S 3 Year of Manufacture S, (P = 1993, R = 1994, S = 1995, T = 1996, V = 1997, W = 1998, X = 1999, Y = 2000, 1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004) 4 Manufacturing Location (E = England) 5 Machine Serial Number (0527001) The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. Unit Identification The engine serial number is stamped on a plate 2Y or 3Y which is fastened to the right side of the cylinder block, near the fuel filter. Note: For machines with the JCB 444 Series engine, see Section K, Technical Data. Fig 2. 412S Machines 1 2 3 4 5 SLP 412S0 S E 0527001

Section 1 - General Information Identifying your Machine Identification Plates 1 - 3 1 - 3 9803/4170-10 Fig 3. 414S Machines Typical Engine Identification Number 1 Engine Type, a AA = 4 cylinder naturally aspirated b AB = 4 cylinder turbo 2 Build Number 3 Country of Origin 4 Engine Sequence Number 5 Year of Manufacture Transmission Identification The Transmission serial number is stamped on plate 4Z or 5Z as shown. Fig 4. 412S Machines 1 2 3 4 5 AA 50261 U 500405 P

Section 1 - General Information Identifying your Machine Identification Plates 1 - 4 1 - 4 9803/4170-10 Fig 5. 414S Machines

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JCB Excavator Factory Service & Work Shop Manual

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