JCB 412S WHEELED LOADER Service Repair Manual SN 535000 PDF

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
Publication No.
9803/4170-14
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 left intentionally blank
1-0 9803/4170-10 1-0

Contents Page No.

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
1-i 1-i
Contents Page No.
1 - ii 1 - ii
Introduction
About this Publication
This publication is designed for the benefit of JCB All sections are listed on the front cover; tabbed divider
Distributor Service Engineers who are receiving, or have cards align directly with individual sections on the front
received, training by JCB Technical Training Department. cover for rapid reference.
These personnel should have a sound knowledge of Where a torque setting is given as a single figure it may be
workshop practice, safety procedures, and general varied by plus or minus 3%. Torque figures indicated are
techniques associated with the maintenance and repair of for dry threads, hence for lubricated threads may be
hydraulic earthmoving equipment. reduced by one third.
Renewal of oil seals, gaskets, etc., and any component 'Left Hand' and 'Right Hand' are as viewed from the rear of
showing obvious signs of wear or damage is expected as the machine facing forwards.
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any This Service Manual covers the following machines:
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt. 412S Wheeled Loading Shovel from machine serial
Finally, please remember above all else SAFETY MUST number 535000
COME FIRST!
414S Wheeled Loading Shovel from machine serial
The manual is compiled in sections, the first three are number 537000
numbered and contain information as follows:
1 General Information - includes torque settings and number 543000
service tools.
The information provided in this manual for the 414S
2 Care & Safety - includes warnings and cautions machine also applies to the 416S machine except where
pertinent to aspects of workshop procedures etc. speciified.
3 Routine Maintenance - includes service schedules Smoothshift Transmission introduced from the following
and recommended lubricants for all the machine. serial numbers:
The remaining sections are alphabetically coded and deal 412S Wheeled Loading Shovel from machine serial
with Dismantling, Overhaul etc. of specific components, for number 535500
example:
number 537300
A Attachments
B Body & Framework...etc. 416S Wheeled Loading Shovel from machine serial
number 543100
The page numbering in each alphabetically coded section
is not continuous. This allows for the insertion of new items JCB 444 Series engine added to 412S Wheeled Loading
in later issues of the manual. Shovel from machine serial number 1242000.
Section contents, technical data, circuit descriptions,

operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
1-1 9803/4170-10 1-1


Identification Plates
Identification Plate identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
Your machine has an identification plate 1X mounted on replacement parts are ordered.
the left hand side of the machine on the loader arm pillar.
The serial numbers of the machine and its major units are The machine and engine serial numbers can help identify
stamped on the plate. 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 1.
Explanation of Vehicle Identification

Number (VIN)
1 2 3 4 5
SLP 412S0 S E 0527001
1 World Manufacturer Identification, SLP = JCB
2 Machine Model, 412S0 = 412S
3 Year of Manufacture S, (P = 1993, R = 1994, S = Fig 2. 412S Machines

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
1-2 9803/4170-10 1-2

Transmission Identification
The Transmission serial number is stamped on plate 4Z or
5Z as shown.
Fig 3. 414S Machines
Typical Engine Identification Number
1 2 3 4 5
AA 50261 U 500405 P
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 Fig 4. 412S Machines
5 Year of Manufacture
1-3 9803/4170-10 1-3

Fig 5. 414S Machines
1-4 9803/4170-10 1-4

Torque Settings
Zinc Plated Fasteners (golden finish)
Use only where no torque setting is specified in the text. Metric Grade 8.8 Bolts
Values are for dry threads and may be within three per cent
of the figures stated. For lubricated threads the values
should be REDUCED by one third. Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
UNF Grade `S' Bolts (A/F) mm
M5 (5) 8 7 0.7 5
Bolt size Torque Settings
M6 (6) 10 12 1.2 9
Dia. (mm) Hexagon Nm kgf m lbf ft
M8 (8) 13 28 3.0 21
(A/F) mm
M10 (10) 17 56 5.7 42
1/4 6.3 7/16 14 1.4 10
M12 (12) 19 98 10 72
5/16 7.9 1/2 28 2.8 20
M16 (16) 24 244 25 180
3/8 9.5 9/16 49 5.0 36
M18 (18) 27 350 36 258
7/16 11.1 5/8 78 8.0 58
M20 (20) 30 476 48 352
1/2 12.7 3/4 117 12.0 87
M24 (24) 36 822 84 607
9/16 14.3 13/16 170 17.3 125
M30 (30) 46 1633 166 1205
5/8 15.9 15/16 238 24.3 175
M36 (36) 55 2854 291 2105
3/4 19 1 1/8 407 41.5 300
7/8 22.2 1 5/16 650 66.3 480 Rivet Nut Bolts/Screws
1 25.4 1 1/2 970 99.0 715
1 1/4 31.7 1 7/8 1940 198.0 1430 Bolt size Torque Settings (for
steel rivet nuts)
1 1/2 38.1 2 1/4 3390 345.0 2500
Dia. (mm) Nm kgf m lbf ft
M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
1-5 9803/4170-10 1-5

Torque Settings
JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)
JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)
Note: All adapters, elbows and hoses should be tightened

to JCB standard torque settings unless stated otherwise.
Fig 1.
1-6 9803/4170-10 1-6

Torque Settings
JCB Standard Torque Settings for Hose Ends and Flanged Fittings (Colour Coded)
JCB Standard Torque Settings for Hose Ends and Flanged Fittings
(Colour Coded)
Note: All adapters, elbows and hoses should be tightened

to JCB standard torque settings unless stated otherwise.
Fig 2.
1-7 9803/4170-10 1-7

Service Tools
Numerical List Section B - Body and Framework
The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
removal and replacement of Body and Framework parts. expected that such general tools will be available in any
These tools are available from JCB Service. well equipped workshop or be available locally from any
good tool supplier.
Part Description Tool Detail

Number Reference
825/99849 Dummy Boss K Fig 12. ( T 1-11)
825/99850 Bearing Locator K Fig 12. ( T 1-11)
826/01179 M6 x 16mm Rivet Nut K Fig 1. ( T 1-9)
892/00842 Glass Lifter K Fig 3. ( T 1-9)
892/00843 Glass Stand K Fig 2. ( T 1-9)
892/00844 Long Knife K Fig 11. ( T 1-11)
892/00846 Glass Extractor (Handles) K Fig 8. ( T 1-10)
892/00847 Nylon Spatula K Fig 4. ( T 1-9)
892/00848 Wire Starter K Fig 6. ( T 1-10)
892/00849 Braided Cutting Wire K Fig 10. ( T 1-11)
926/15500 Rubber Spacer Blocks K Fig 5. ( T 1-10)
992/12800 Cut-Out Knife K Fig 7. ( T 1-10)
992/12801 'L' Blades K Fig 9. ( T 1-11)
1-8 9803/4170-10 1-8

Service Tools
Tool Detail Reference Section B - Body and Framework
Note: essential for preparing new glass prior to

installation.
Fig 1. Fig 3. 892/00842

Note: 826/01179 M6 x 16mm Rivet Nut, 826/01106 M6 Note: - minimum 2 off - essential for glass installation, 2
x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, required to handle large panes of glass. Ensure suction
826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x cups are protected from damage during storage.
26mm Rivet Nut
Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
Fig 4. 892/00847
Note: - general tool used for smoothing sealants - also
used to re-install glass in rubber glazing because metal
tools will chip the glass edge.
Fig 2. 892/00843
1-9 9803/4170-10 1-9

Service Tools
Fig 5. 926/15500
Fig 7. 992/12800
Note: - used to provide the correct set clearance
between glass edge and cab frame. (unit quantity = 500 Note: - used to remove broken glass.
off)
Fig 8. 892/00846
Note: - used with braided cutting wire (below) to cut out
broken glass.
Fig 6. 892/00848
Note: - used to access braided cutting wire (below)
through original polyurethane seal.
1 - 10 9803/4170-10 1 - 10
Service Tools
Fig 9. 992/12801
Note: - 25 mm (1 in) cut - replacement blades for cut-out
knife (above), (unit quantity = 5 off)
Fig 12. 825/99849

Note: - used with bearing locator to set up Upper Centre
Pivot.
Fig 10. 892/00849

Note: - consumable heavy duty cut-out wire used with
the glass extraction tool (above), (approx 25 m length)
Fig 13. 825/99850

Note: - used with dummy bush to set up Upper Centre
Pivot.
Fig 11. 892/00844

Note: - used to give extended reach for normally
inaccessible areas.
1 - 11 9803/4170-10 1 - 11
Service Tools
Fig 14. Cab Prop

Note: - used to support cab in the raised position. A
minimum of 2 are required to support the side where
work is being carried out. It is recommended that 4 are
used to support the cab level.
Manufacture from mild steel.
Tube wall and plate minimum thickness must be 3 mm.
1 - 12 9803/4170-10 1 - 12
Service Tools
Numerical List Section C - Electrics
Numerical List Section C - Electrics
testing electrics. These tools are available from JCB expected that such general tools will be available in any
Service . well equipped workshop or be available locally from any
good tool supplier.

Number Reference
892/00282 Shunt K Fig 15. ( T 1-14)
892/00283 Tool Kit Case K Fig 15. ( T 1-14)
892/00284 Digital Tachometer K Fig 15. ( T 1-14)
892/00285 Hyd. Oil Temperature Probe K Fig 15. ( T 1-14)
892/00286 Surface Temperature Probe K Fig 15. ( T 1-14)
892/00298 Fluke Meter K Fig 15. ( T 1-14)
993/85700 Battery Tester K Fig 16. ( T 1-14)
1 - 13 9803/4170-10 1 - 13
Service Tools
Tool Detail Reference Section C - Electrics
Tool Detail Reference Section C - Electrics
Fig 16. 993/85700
Fig 15.
1 892/00283 Tool Kit Case
2 892/00298 Fluke Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Venture Microtach Digital Tachometer
5 892/00282 100 amp Shunt - open type
6 892/00285 Hydraulic Temperature Probe
1 - 14 9803/4170-10 1 - 14
Service Tools
Numerical List Section E - Hydraulics
testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any
are available from JCB Service . well equipped workshop or be available locally from any
good tool supplier.

Number Reference
1406/0011 Bonded Washer K Fig 19. ( T 1-18)
1604/0006 Adapter K Fig 20. ( T 1-18)
1612/0006 Adapter K Fig 20. ( T 1-18)
816/00189 Blanking Cap K Fig 22. ( T 1-19)
816/15118 Pressure Test Adapter K Fig 23. ( T 1-19)
816/20008 Adapter K Fig 20. ( T 1-18)
892/00039 Spool Clamp K Fig 26. ( T 1-20)
892/00055 Blanking Plug K Fig 21. ( T 1-19)
892/00074 Female Connector K Fig 24. ( T 1-19)
892/00137 Micro-Bore Hose K Fig 27. ( T 1-20)
892/00223 Hand Pump K Fig 27. ( T 1-20)
892/00239 Charging Tool K Fig 28. ( T 1-20)
1 - 15 9803/4170-10 1 - 15
Service Tools

Number Reference
892/00253 Pressure Test Kit K Fig 17. ( T 1-18)
892/00255 Pressure Test Adaptor K Fig 23. ( T 1-19)
892/00268 Flow Monitoring Unit K Fig 20. ( T 1-18)
892/00269 Sensor Head K Fig 20. ( T 1-18)
892/00270 Load Valve K Fig 20. ( T 1-18)
892/00274 Adapter K Fig 27. ( T 1-20)
892/00275 Adapter K Fig 20. ( T 1-18)
892/00279 Gauge K Fig 27. ( T 1-20)
892/00309 A.R.V. Pressure Test Kit K Fig 29. ( T 1-21)
892/00335 A.R.V. Cartridge Removal Tool K Fig 29. ( T 1-21)
892/00340 Test Block Body K Fig 29. ( T 1-21)
892/00341 Setting Body K Fig 29. ( T 1-21)
892/00343 Spanner K Fig 29. ( T 1-21)
892/00345 Anti-cavitation Lock Out Bung K Fig 29. ( T 1-21)
892/00706 Test Probe K Fig 27. ( T 1-20)
892/01043 Adapter K Fig 28. ( T 1-20)
992/09300 Spanner K Fig 25. ( T 1-20)
992/09400 Spanner K Fig 25. ( T 1-20)
992/09500 Spanner K Fig 25. ( T 1-20)
992/09600 Spanner K Fig 25. ( T 1-20)
992/09700 Spanner K Fig 25. ( T 1-20)
992/10000 Spanner K Fig 25. ( T 1-20)
992/10100 Spool Clamp K Fig 26. ( T 1-20)
993/68300 Adjusting Pin K Fig 29. ( T 1-21)
1 - 16 9803/4170-10 1 - 16
Service Tools
The following parts are replacement items for kits and Replacement items for kit no. 892/00253
would normally be included in the kit numbers above.

Number Reference
892/00201 Replacement Gauge K Fig 17. ( T 1-18)
892/00254 Replacement Hose K Fig 17. ( T 1-18)
1 - 17 9803/4170-10 1 - 17
Service Tools
Tool Detail Reference Section E- Hydraulics
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
Fig 19. Bonded Washers

Fig 17. Hydraulic Circuit Pressure test Kit 1406/0011 1/4 in BSP
892/00253 Pressure Test Kit 1406/0018 1/2 in BSP
2
892/00201 Replacement gauge 0-20 bar (0-300 lbf/in ) 1406/0014 5/8 in BSP
892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2) 1406/0021 3/4 in BSP
892/00203 Replacement gauge 0-400 bar (0-6000 lbf/ 1406/0029 1.1/4 in BSP
in2)
892/00254 Replacement Hose
Fig 20. Flow Test Equipment

892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 to 100 l/min (0 to 22 UK
gal/min)
892/00270 Load Valve
Fig 18. Pressure Test `T' Adapters
1406/0021Bonded Washer
1 - 18 9803/4170-10 1 - 18
Service Tools
1604/0006 Adapter 3/4 in M x 3/4 M BSP

1612/0006 Adapter 3/4 in F x 3/4 M BSP
Fig 23. Pressure Test Adapters

892/00255 1/4 in BSP x Test Point
Fig 21. Female Cone Blanking Cap
892/00259 1 in BSP x Test Point
892/00055 1/4 in BSP
892/00260 1.1/4 in BSP x Test Point
892/00056 3/8 in BSP
892/00261 5/8 in UNF x Test Point
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
Fig 24. Female Connectors

892/00074 3/8 in BSP x 3/8 in BSP
Fig 22. Male Cone Blanking Cap
892/00075 1/2 in BSP x 1/2 in BSP
816/00294 1/4 in BSP
892/00076 5/8 in BSP x 5/8 in BSP
816/00189 3/8 in BSP
892/00077 3/4 in BSP x 3/4 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP
1 - 19 9803/4170-10 1 - 19
Service Tools
Fig 25. Hexagon Spanners for Ram Pistons and End

Caps Fig 27. Hand Pump Equipment
992/09300 55 mm 892/00223 Hand Pump
992/09400 65 mm 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
992/09500 75 mm 892/00274 Adapter 1/4 in. M BSP x 3/8 in. M BSP Taper
992/09600 85 mm 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
992/09700 95 mm 892/00706 Test Probe
992/10000 125 mm 892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Fig 28. Accumulator Charge Equipment

Fig 26. Spool Clamps 892/00239 Charging Tool (Diaphragm Accumulators)
892/00039 Spool Clamp 892/01042 Charging Tool (Diaphragm Accumulators)
992/10100 Spool Clamp 892/01043 Adatper (use with 892/01042)
892/00948 Charging Tool (Piston Accumulators)
1 - 20 9803/4170-10 1 - 20
Service Tools
Fig 29. Components for Valve Block A.R.V. Testing

892/00309 A.R.V. Pressure Test Kit
1 892/00340 Test Block Body
2 892/00341 Setting Body
3 993/68300 Adjusting Pin
4 892/00343 Spanner
5 892/00345 Anti-cavitation Lock Out Bung
6 892/00335 A.R.V. Cartridge Removal Tool
1 - 21 9803/4170-10 1 - 21
Service Tools
Numerical List Section F - Transmission
Numerical List Section F - Transmission
good tool supplier.

Number Reference
892/00817 Heavy Duty Socket K Fig 31. ( T 1-23)
892/00859 Spanner Stake Nut K Fig 34. ( T 1-24)
892/00860 Bearing Shim Remover K Fig 37. ( T 1-24)
892/00861 Bearing Remover Base Tool K Fig 37. ( T 1-24)
892/00862 Tab Washer Fitting Tool K Fig 34. ( T 1-24)
892/00863 Blanking Plate Fitting Tool K Fig 38. ( T 1-24)
892/00864 PD90 Locknut Spanner K Fig 36. ( T 1-24)
892/00865 Computer Test Harness K Fig 33. ( T 1-23)
892/00866 Computer Test Indicator Box K Fig 33. ( T 1-23)
892/00867 Computer Test Interrogator Box K Fig 33. ( T 1-23)
892/00891 Fitting Tool Assembly K Fig 39. ( T 1-24)
892/00909 Hub Puller K Fig 36. ( T 1-24)
892/01066 Interrogation lead K Fig 40. ( T 1-25)
992/04000 Torque Multiplier K Fig 32. ( T 1-23)
992/07603 Replacer - Bearing Cup K Fig 30. ( T 1-23)
1 - 22 9803/4170-10 1 - 22
Service Tools
Tool Detail Reference Section F - Transmission
Fig 30. 992/07603
Fig 33.
Fig 31. Heavy Duty Socket for Durlock Bolts

892/00817 17 mm A/F x 3/4 in. Square Drive
Fig 32. 992/04000

Note: Use in conjunction with a torque wrench to give a
5:1 multiplication when tightening pinion nuts etc.
892/00865 Computer test harness
892/00866 Computer test indicator box
892/00867 Computer test interrogator box
1 - 23 9803/4170-10 1 - 23
Service Tools
Fig 34. 892/00859

Fig 37.
1 892/00860 Bearing Remover Shim
2 892/00861 Bearing Remover Base Tool
Fig 35. 892/00862
Fig 38. 892/00863
Fig 36. 892/00864
Fig 39. 892/00891
1 - 24 9803/4170-10 1 - 24
Service Tools
Fig 40. 892/01066
Fig 41. 892/01066
1 - 25 9803/4170-10 1 - 25
Service Tools
Numerical List Section K - Engine
Numerical List Section K - Engine
good tool supplier.

Number Reference
892/00041 De-glazing Tool K Fig 42. ( T 1-27)
1 - 26 9803/4170-10 1 - 26
Service Tools
Tool Detail Reference Section K - Engine
Tool Detail Reference Section K - Engine
Fig 42. 892/00041

Note: De-glazing Tool for Cylinder Bores (to assist
bedding-in of new piston rings)
For details of other engine service tools refer to Perkins

Service Manual Publication No. 9806/0100
1 - 27 9803/4170-10 1 - 27
Service Consumables
Sealing and Retaining Compounds
Service Consumables
Sealing and Retaining Compounds
T11-001_3
Table 1.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of 4102/1212 50 ml
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml
components. Gasketing for all sizes of flange where
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be 4101/0651 50 ml
dismantled.
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and 4101/0250 10 ml
retaining nuts, bolts, and screws up to 50 mm 4101/0251 50 ml
diameter, and for hydraulic fittings up to 25 mm
diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 200 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 200 ml (Aerosol)
anaerobic products. 4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of 4104/1557 400 ml (Aerosol)
anaerobic adhesives and sealants.
Direct Glazing Kit For one pane of glass; comprises of: 993/55700
– 1 x Ultra Fast Adhesive (310 ml)

– 1 x Active Wipe 205 (30 ml)
– 1 x Black Primer 206J (30 ml)
– plus applicator nozzle etc.
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml
1 - 28 9803/4170-10 1 - 28
2-0 9803/4170-10 2-0

Contents Page No.

Safety Check List
Safety Notices ......................................................................................... 2 - 1
Safety - Yours and Others ....................................................................... 2 - 2
General Safety ........................................................................................ 2 - 3
Operating Safety ..................................................................................... 2 - 4
Maintenance Safety ................................................................................. 2 - 6
Safety Decals .......................................................................................... 2 - 9
2-i 2-i
Contents Page No.
2 - ii 2 - ii
Safety Check List

Safety Notices
In this publication and on the machine, there are safety

notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1
!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
2-1 9803/4170-10 2-1

Safety Check List
Safety - Yours and Others
Safety - Yours and Others
All construction and agricultural equipment can be

hazardous. When a JCB machine is correctly operated
and properly maintained, it is a safe machine to work
with. But when it is carelessly operated or poorly
maintained it can become a danger to you (the
operator) and others.
Do not work with the machine until you are sure that
you can control it.
Do not start any job until you are sure that you and
those around you will be safe.
If you are unsure of anything, about the machine or the

job, ask someone who knows. Do not assume
anything.
Remember
– BE CAREFUL
– BE ALERT
– BE SAFE
GEN-1-6
As well as the warnings in the following pages, specific

warnings are given throughout the book. This section is
designed to give a safety code for use of the machine
generally and for operation and maintenance practices.
2-2 9803/4170-10 2-2

Safety Check List
General Safety
General Safety
!MWARNING
Decals
Decals on the machine warn you of particular hazards.
You can be injured if you do not obey the decal safety
instructions.
Each decal is attached close to a part of the machine

where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.
Keep all decals clean and readable. Replace lost or

damaged decals. Each decal has a part number
printed on it, use this number to order a new decal
from your JCB distributor.
INT-3-3-3_1
!MWARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained.
INT-1-3-6
!MWARNING
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
2-3 9803/4170-10 2-3

Safety Check List
Operating Safety
Operating Safety
!MWARNING !MWARNING
Controls Fires
You or others can be killed or seriously injured if you If your machine is equipped with a fire extinguisher,
operate the control levers from outside the cab. make sure it is checked regularly. Keep it in the
Operate the control levers only when you are correctly operator's cab until you need to use it.
seated inside the cab.
INT-2-1-3 Do not use water to put out a machine fire, you could
spread an oil fire or get a shock from an elecrical fire.
!MWARNING Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department
Entering/Leaving as quickly as possible. Firefighters should use self-
Entering or leaving the cab or canopy must only be contained breathing apparatus.
made where steps and handrails are provided. Always INT-3-2-7_1
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
!MWARNING
use the machine controls as handholds, use the Engine Panels
handrails. The engine has exposed rotating parts.
INT-2-1-7_1
Do not open the bonnet while the engine is running.
!MWARNING Keep other people clear while you raise the engine
cover using the boom. Do not use the machine with
Exhaust Gases the bonnet open or the cover raised.
Breathing the machine exhaust gases can harm and 5-1-2-1
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation.
If possible, fit an exhaust extension. If you begin to
!MWARNING
feel drowsy, stop the machine at once and get into The machine is fitted with a Roll Over Protection
fresh air. Structure (ROPS) and a Falling Objects Protection
INT-2-1-10_2 Structure (FOPS). You could be killed or seriously
injured if you operate the machine with a damaged or
!MWARNING missing ROPS/FOPS. If the ROPS/FOPS has been in
an accident, do not use the machine until the structure
Ramps and Trailers has been renewed. Modifications and repairs that are
Water, mud, ice, grease and oil on ramps or trailers not approved by the manufacturer may be dangerous
can cause serious accidents. Make sure ramps and and will invalidate the ROPS/FOPS certification.
trailers are clean before driving onto them. Use INT-2-1-9_3
extreme caution when driving onto ramps and trailers.
INT-2-2-6
!MWARNING
Reversing
Reversing at high speeds can cause accidents. Do not
reverse in a high gear with full throttle. Always drive at
a safe speed to suit working conditions.
INT-2-2-9_1
2-4 9803/4170-10 2-4

Safety Check List
Operating Safety
!MWARNING
Communications
Bad communications can cause accidents. Keep
people around you informed of what you will be doing.
If you will be working with other people, make sure any
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on
spoken commands.
INT-2-2-3
!MDANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
INT-2-2-10
2-5 9803/4170-10 2-5

Safety Check List
Maintenance Safety
Maintenance Safety
!MWARNING !MDANGER
Metal Splinters Electrolyte
You can be injured by flying metal splinters when Battery electrolyte is toxic and corrosive. Do not
driving metal pins in or out. Use a soft faced hammer breathe the gases given off by the battery. Keep the
or drift to remove and fit metal pins. Always wear electrolyte away from your clothes, skin, mouth and
safety glasses. eyes. Wear safety glasses.
INT-3-1-3 INT-3-2-1_3
!MWARNING !MWARNING
Communications Accumulators
Bad communications can cause accidents. If two or The accumulators contain hydraulic fluid and gas at
more people are working on the machine, make sure high pressure. Prior to any work being carried out on
each is aware of what the others are doing. Before systems incorporating accumulators, the system
starting the engine make sure the others are clear of pressure must be exhausted by a JCB distributor, as
the danger areas; examples of danger areas are: the the sudden release of the hydraulic fluid or gas may
rotating blades and belt on the engine, the cause injury.
attachments and linkages, and anywhere beneath or INT-3-1-17
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
!MWARNING
Jacking
!MWARNING A machine can roll off jacks and crush you unless the
wheels have been chocked. Always chock the wheels
Asbestos at the opposite end of the machine that is to be jacked.
Asbestos dust can damage your lungs. Some engine Do not work underneath a machine supported only by
gaskets contain asbestos. Do not dismantle the jacks. Always support a jacked-up machine on axle
engine or exhaust system; get these jobs done by a stands before working underneath it.
qualified person who has a copy of the engine service INT-3-2-8
manual.
5-1-6-1
!MWARNING
!MWARNING Diesel Fuel
Diesel fuel is flammable; keep naked flames away from
Battery Gases the fuel system. Do not smoke while refuelling or
Batteries give off explosive gases. Keep flames and working on the fuel system. Do not refuel with the
sparks away from the battery. Do not smoke close to engine running. There could be a fire and injury if you
the battery. Make sure there is good ventilation in do not follow these precautions.
closed areas where batteries are being used or INT-3-2-2_1
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8
2-6 9803/4170-10 2-6

Safety Check List
Maintenance Safety
!MWARNING !MWARNING
Hot Coolant Hydraulic Pressure
The cooling system is pressurised when the engine is Hydraulic fluid at system pressure can injure you.
hot. Hot coolant can spray out when you remove the Before disconnecting or connecting hydraulic hoses,
filler cap. Let the system cool before removing the stop the engine and operate the controls to release
filler cap. To remove the cap; turn it to the first notch pressure trapped in the hoses. Make sure the engine
and let the system pressure escape, then remove the cannot be started while the hoses are open.
cap. INT-3-1-11_1
INT-3-2-9_1
!MWARNING
!MWARNING If you try to charge a frozen battery, or jump start and
Petrol run the engine, the battery could explode. Do not use
Do not use petrol in this machine. Do not mix petrol a battery if its electrolyte is frozen. To prevent the
with the diesel fuel; in storage tanks the petrol will rise battery electrolyte from freezing, keep the battery at
to the top and form flammable vapours. full charge.
INT-3-1-6 0125
!MWARNING !MCAUTION
Oil Cleaning
Oil is toxic. If you swallow any oil, do not induce Cleaning metal parts with incorrect solvents can
vomiting, seek medical advice. Used engine oil cause corrosion. Use only recommended cleaning
contains harmful contaminants which can cause skin agents and solvents.
cancer. Do not handle used engine oil more than INT-3-2-11
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
!MCAUTION
diesel fuel or paraffin to clean your skin. 'O' rings, Seals and Gaskets
INT-3-2-3 Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
!MWARNING Renew whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
Electrical Circuits thinners near 'O' rings and seals.
Understand the electrical circuit before connecting or INT-3-2-12
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!MWARNING
Soft Ground
!MWARNING A machine can sink into soft ground. Never work
under a machine on soft ground.
Fluid Under Pressure INT-3-2-4
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
2-7 9803/4170-10 2-7

Safety Check List
Maintenance Safety
!MWARNING !MWARNING
Battery Terminals Hydraulic Hoses
The machine is negatively earthed. Always connect Damaged hoses can cause fatal accidents. Inspect the
the negative pole of the battery to earth. hoses regularly for:
When connecting the battery, connect the earth (-) – Damaged hose ends
lead last. – Chafed outer covers
– Balloned outer covers
When disconnecting the battery, disconnect the earth
(-) lead first. – Kinked or crushed hoses
INT-3-1-9 – Embedded armouring in outer covers
– Displaced end fittings.
!MWARNING INT-3-3-2
Certain seals and gaskets (e.g. crankshaft oil seal) on

JCB machines contain fluoroelastomeric materials
such as Viton, Fluorel 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 (572°F) 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 (572°F) (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn:
1 Thoroughly wash contaminated area with 10%

calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains.
2 Thoroughly wash contaminated area with

detergent and water.
3 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 FLUOROELASTOMERIC MATERIALS.

INT-3-3-5_3
2-8 9803/4170-10 2-8

Safety Check List
Safety Decals
Safety Decals

where there is a possible hazard. Read and make sure you
understand the safety message before you work with or on
that part of the machine.

damaged decals. The decals and their attachment points
are as illustrated. Each decal has a part number printed on
it, use this number to order a new decal from your JCB
dealer.
!MWARNING
If you need eye-glasses for reading, make sure you
wear them when reading the safety decals. Decals are
strategically placed around the machine to remind you
of possible hazards. Do not over-stretch or place
yourself in dangerous positions to read the decals.
INT-3-3-4_1
!MWARNING
Decals
You can be injured if you do not obey the decal safety
instructions.

where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.

damaged decals. Each decal has a part number
printed on it, use this number to order a new decal
from your JCB distributor.
INT-3-3-3_1
2-9 9803/4170-10 2-9

Safety Check List
Safety Decals
Fig 1.
2 - 10 9803/4170-10 2 - 10
3-0 9803/4170-12 3-0

Contents Page No.

Routine Maintenance
Lubricants and Capacities - Pre-Smoothshift Transmission .................... 3 - 1
Lubricants and Capacities - Smoothshift Transmission ........................... 3 - 3
Lubricants and Capacities - Tier 2 Engines with Smoothshift .................. 3 - 5
Lubricants and Capacities - 414S From 537400 & 416S From 543250 .. 3 - 7
Health and Safety .................................................................................... 3 - 8
Service Schedules ................................................................................. 3 - 12
Greasing ................................................................................................ 3 - 17
Loader Arm Safety Strut ........................................................................ 3 - 21
Articulation Lock .................................................................................... 3 - 22
Hydraulic System ................................................................................... 3 - 24
Transmission ......................................................................................... 3 - 26
Front and Rear Axles ............................................................................. 3 - 32
Engine ................................................................................................... 3 - 34
Fuel System ........................................................................................... 3 - 41
Cooling System ..................................................................................... 3 - 58
Fan Belts ............................................................................................... 3 - 70
Cab Heater Filters ................................................................................. 3 - 75
Air Filter ................................................................................................. 3 - 79
Routine Maintenance (412S from Serial No. 1242000)

Service Requirements ........................................................................... 3 - 86
Health and Safety .................................................................................. 3 - 88
Service Schedules ................................................................................. 3 - 92
Lubricants and Capacities ..................................................................... 3 - 96
Cleaning the Machine ............................................................................ 3 - 97
Inspections ............................................................................................ 3 - 98
Greasing ................................................................................................ 3 - 99
Automatic Greasing System ................................................................ 3 - 102
Engine Covers ..................................................................................... 3 - 105
Rear Grille ........................................................................................... 3 - 106
Heater Door ......................................................................................... 3 - 107
Checking the ROPS/FOPS Structure .................................................. 3 - 108
Articulation Lock .................................................................................. 3 - 109
Loader Arm Safety strut ....................................................................... 3 - 111
Electrical System ................................................................................. 3 - 112
Engine ................................................................................................. 3 - 114
Fuel System ......................................................................................... 3 - 123
Hydraulic System ................................................................................. 3 - 129
Transmission ....................................................................................... 3 - 131
Front and Rear Axles ........................................................................... 3 - 133
Tyres and Wheels ................................................................................ 3 - 135
Windscreen Washers .......................................................................... 3 - 136
Cab Heater Filters ............................................................................... 3 - 137
Routine Maintenance (414S from Serial No. 1242500, 416S from 1243500)
Service Requirements ......................................................................... 3 - 139
Health and Safety ................................................................................ 3 - 141
Service Schedules ............................................................................... 3 - 145
Lubricants and Capacities ................................................................... 3 - 149
Cleaning the Machine .......................................................................... 3 - 150
Checking for Damage .......................................................................... 3 - 151
Seat Belt .............................................................................................. 3 - 152
Greasing .............................................................................................. 3 - 153
3-i 3-i
Contents Page No.

Access Panels ..................................................................................... 3 - 159
Engine ................................................................................................. 3 - 167
Fuel System ......................................................................................... 3 - 174
Transmission ....................................................................................... 3 - 180
Axles .................................................................................................... 3 - 182
Tyres and Wheels ................................................................................ 3 - 184
Heating and Ventilation ....................................................................... 3 - 185
Front Window Washers ....................................................................... 3 - 186
Routine Maintenance (412S from Serial No. 1421800

Service Requirements ......................................................................... 3 - 187
Health and Safety ................................................................................ 3 - 189
Service Schedules ............................................................................... 3 - 193
Lubricants and Capacities ................................................................... 3 - 197
Cleaning the Machine .......................................................................... 3 - 198
Checking for Damage .......................................................................... 3 - 199
Seat Belt .............................................................................................. 3 - 200
Greasing .............................................................................................. 3 - 201
Access Panels ..................................................................................... 3 - 207
Engine Air Filter ................................................................................... 3 - 216
Engine ................................................................................................. 3 - 218
Fuel System ......................................................................................... 3 - 227
Transmission ....................................................................................... 3 - 237
Axles .................................................................................................... 3 - 239
Tyres and Wheels ................................................................................ 3 - 241
Heating and Ventilation ....................................................................... 3 - 242
Front Window Washers ....................................................................... 3 - 243
3 - ii 3 - ii
Section 3 - Maintenance
Routine Maintenance
Lubricants and Capacities - Pre-Smoothshift Transmission
Routine Maintenance
Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.
Table 1.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil 412S To Ser. No
535352
-18 to 0° C 10.7 litres (2.4 UK gal) JCB Torque Converter Fluid
-10 to 50° C 414S To Ser. No API CE, MIL-L-
537160 2104C/D
16.0 litres (3.5 UK gal) JCB 15W/40 Multigrade
Engine Oil 412S From Ser. No JCB Super Multigrade 15w/40 CF-4/SG, SAE
535353 15w/40
10.7 litres (2.4 UK gal) -10°C to +50°C (14°F to 122°F)
414S From Ser. No JCB Super Multigrade 10w/30 CF-4/SG, SAE
537161 10w/30
16.0 litres (3.5 UK gal) -15°C to +40°C (5°F to 104°F)
Gearbox
412S (1)
18 litres (4.1 UK gal) JCB Torque Converter Fluid API CE, MIL-L-
2104C/D
414S (1)
23 litres (5.1 UK gal) API CE, MIL-L-
2104C/D
Axles
412S 24.0 litres (5.3 UK gal) JCB Special Gear Oil Plus API GL4(2)
414S 23.0 litres (5.1 UK gal)
416S 25.0 litres (5.6 UK gal)
(3)
Hydraulic System
412S 110 litres (24.8 UK gal) JCB HP32 Hydraulic Fluid ISO VG32
414S 125 litres (27.5 UK gal)
Cooling System
3-1 9803/4170-12 3-1

Routine Maintenance

SPECIFICATION
412S 26 litres (5.9 UK gal) JCB High Performance Antifreeze and Inhibitor ASTM D6210
(see K Coolant Mixtures ( T 3-58))
414S 50 litres (11 UK gal)
Fuel System (4)
412S 125 litres (27.5 UK gal) Diesel Oil (see K Types of Fuel ( T 3-41)) ASTM D975-66T
Nos. 1D, 2D.
Nos. 1D, 2D.
Grease Points JCB HP Grease Lithium based
(1) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(2) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(3) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and
watch the level indicator.
(4) A 75 litre (16.5 UK gal) auxiliary fuel tank is available as an option
Note: If JCB Special MPL Grease is used, all 100 hour

greasing operations must be caried out at TEN (10) HOUR
intervals.
Note: Biodegradeable Hydraulic Fluid is a factory option

ONLY. Replenish with JCB Biodegradeable Multigrade
Hydraulic Fluid. For further information, contact Wheeled
Loader Technical Service.
3-2 9803/4170-12 3-2

Routine Maintenance
Lubricants and Capacities - Smoothshift Transmission
Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.
Table 2.
SPECIFICATION
Engine Oil 412S
-10 to 50° C 10.7 litres (2.4 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
414S/416S API CH-4/A3
16.0 litres (3.5 UK gal)
Gearbox(1)
414S/416S 24 litres (5.3 UK gal) JCB HP Universal ATF ZF TE-MIL 09, 11,
12, 14
412S 24 litres (5.3 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4/A3
Axles
412S 24.0 litres (5.3 UK gal) JCB Special HP Gear Oil API GL4(2)
(3)
Hydraulic System
414S 125 litres (27.5 UK gal) JCB Extreme Performance Multigrade ISO VG46
Hydraulic Fluid 46
Cooling System
414S/416S 50 litres (11.0 UK gal)
(4)
Fuel System
Nos. 1D, 2D.
3-3 9803/4170-12 3-3

Routine Maintenance
(4) A 75 litre (16.5 UK gal)(412S), 110 litre (16.5 UK gal)(414S/416S) auxiliary fuel tank is available as an option.

intervals.

Hydraulic Fluid. For further information, contact
Earthmovers Technical Service.
Note: Smoothshift machine serial numbers as follows:

412S from Serial No. 535500, 414S from Serial No.
537300, 416S from Serial No. 543100
3-4 9803/4170-12 3-4

Routine Maintenance
Lubricants and Capacities - Tier 2 Engines with Smoothshift
Note: New engines DO NOT require a running-in period. filled at the factory with JCB Extreme Performance 15W/
The engine/machine should be used in a normal work 40. (See below for full specification.). This oil should be
cycle immediately; glazing of the piston cylinder bores, drained after the first 500 hours operation. It is essential
resulting in excessive oil consumption, could occur if the that the drained JCB Extreme Performance 15W/40 is
engine is gently run-in. Under no circumstances should the replaced only by the lubricant recommended below. (See
engine be allowed to idle for extended periods; (e.g. K Service Schedules ( T 3-12) for Tier 2 requirements.)
warming up without load). Engines of new machines are
Table 3.
SPECIFICATION
Engine Oil (Tier 2) 412S From Ser. No
535650
10.9 litres (2.4 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4/A3
CAUTION: DO NOT USE ORDINARY ENGINE OIL FOR TIER 2 ENGINES
Gearbox(1)
414S/416S 24 litres (5.3 UK gal) JCB HP Universal ATF ZF TE-MIL 09, 11,
12, 14
412S 24 litres (5.3 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4/A3
Axles
412S 24.0 litres (5.3 UK gal) JCB Special HP Gear Oil API GL4(2)
(3)
Hydraulic System
414S 125 litres (27.5 UK gal) JCB Extreme Performance Multigrade ISO VG46
Hydraulic Fluid 46
Cooling System
414S/416S 50 litres (11.0 UK gal)
(4)
Fuel System
Nos. 1D, 2D.
3-5 9803/4170-12 3-5

Routine Maintenance
(4) A 75 litre (16.5 UK gal)(412S), 110 litre (16.5 UK gal)(414S/416S) auxiliary fuel tank is available as an option.

intervals.

Hydraulic Fluid. For further information, contact
Earthmovers Technical Service.
Note: Smoothshift machine serial numbers as follows:

412S from Serial No. 535500, 414S from Serial No.
537300, 416S from Serial No. 543100
Note: Engine Oil (Tier 2) 412S from Machine Number

535650. Engine Oil Must conform to the above standard.
3-6 9803/4170-12 3-6

Routine Maintenance
Lubricants and Capacities - 414S From 537400 & 416S From 543250
Lubricants and Capacities - 414S From 537400 & 416S From 543250
Note: New engines DO NOT require a running-in period. Engine Oil. This oil should be drained after the first 500
The engine/machine should be used in a normal work hours operation and the engine filled with the appropriate
cycle immediately; glazing of the piston cylinder bores, recommended grade as shown in the lubrication chart.
resulting in excessive oil consumption, could occur if the JCB Extreme Performance Engine Oil should also be used
engine be allowed to idle for extended periods; (e.g. machine. It is essential that the JCB Extreme Performance
warming up without load). Engines of new machines are oil is replaced by the lubricant recommended below.
filled at the factory with JCB Extreme Performance 15W/40
Table 4.
SPECIFICATION
Engine Oil (Tier 2)
14 litres (3.1 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4/A3
CAUTION: DO NOT USE ORDINARY ENGINE OIL FOR TIER 2 ENGINES
Gearbox
30 litres (6.6 UK gal) JCB Torque Converter Fluid API CE, MIL-L-
2104C/D
Front Axle 23 litres (5.1 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Rear Axle 23 litres (5.1 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Hydraulic System(1)
130 litres (28.6 UK gal) JCB Hydraulic Fluid ISO VG46
Multigrade
Fuel System(2)
140 litres (30.1 UK gal) Diesel Oil (see K Types of Fuel ( T 3-41)) ASTM D975-66T
Nos. 1D, 2D.
Cooling System
35 litres (7.7 UK gal) JCB High Performance Antifreeze and Inhibitor ASTM D6210
(see K Coolant Mixtures (414S from Serial
No. 537400 & 416S from Serial No.
543250) ( T 3-67))
(2) An optional additional fuel tank of 110 litres (24.2 UK gal) can be fitted.
3-7 9803/4170-12 3-7

Routine Maintenance
Health and Safety
Health and Safety

T3-001_3
Lubricants The collection and disposal of used oil should be in

accordance with any local regulations. Never pour used
Introduction engine oil into sewers, drains or on the ground.
It is most important that you read and understand this Handling

information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it New Oil
too.
There are no special precautions needed for the handling
Hygiene or use of new oil, beside the normal care and hygiene
practices.
JCB lubricants are not a health risk when used properly for
their intended purposes. Used Oil
However, excessive or prolonged skin contact can remove Used engine crankcase lubricants contain harmful
the natural fats from your skin, causing dryness and contaminants.
irritation.
Here are precautions to protect your health when handling
Low viscosity oils are more likely to do this, so take special used engine oil:
care when handling used oils, which might be diluted with
fuel contamination. 1 Avoid prolonged, excessive or repeated skin contact
with used oil.
Whenever you are handling oil products you should
maintain good standards of care and personal and plant 2 Apply a barrier cream to the skin before handling
hygiene. For details of these precautions we advise you to used oil. Note the following when removing engine oil
read the relevant publications issued by your local health from skin:
authority, plus the following.
a Wash your skin thoroughly with soap and water.
Storage
b Using a nail brush will help.
Always keep lubricants out of the reach of children.
c Use special hand cleansers to help clean dirty
hands.
Never store lubricants in open or unlabelled containers.
d Never use petrol, diesel fuel, or paraffin for
Waste Disposal
washing.
!MCAUTION 3 Avoid skin contact with oil soaked clothing.

It is illegal to pollute drains, sewers or the ground. 4 Don't keep oily rags in pockets.
Clean up all spilt fluids and/or lubricants.
5 Wash dirty clothing before re-use.
Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with 6 Throw away oil-soaked shoes.
local regulations. Use authorised waste disposal sites.
INT-3-2-14
All waste products should be disposed of in accordance

with all the relevant regulations.
3-8 9803/4170-12 3-8

Routine Maintenance
Health and Safety
First Aid - Oil
Eyes
In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical

advice.
Skin
In the case of excessive skin contact, wash with soap and

water.
Spillage
Absorb on sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal
area.
Fires
!MWARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1
3-9 9803/4170-12 3-9

Routine Maintenance
Health and Safety
Battery Warning Symbols
!MWARNING The following warning symbols may be found on the

battery.
Batteries give off an explosive gas. Do not smoke
when handling or working on the battery. Keep the Symbol Meaning
battery away from sparks and flames.
Keep away from children.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
metallic items (watches, rings, zips etc) away from the
battery terminals. Such items could short the Shield eyes.
terminals and burn you.
Set all switches in the cab to OFF before

disconnecting and connecting the battery. When
disconnecting the battery, take off the earth (-) lead
first. No smoking, no naked flames, no sparks.
Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you
have installed the battery in the machine, wait five
Explosive Gas.
minutes before connecting it up.
When reconnecting, fit the positive (+) lead first.
First Aid - Electrolyte

Battery acid.
Do the following if electrolyte:
GETS INTO YOUR EYES

Note operating instructions.
Immediately flush with water for 15 minutes, always get
medical help.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.
!MCAUTION
Do not disconnect the battery while the engine is
GETS ONTO YOUR SKIN running, otherwise the electrical circuits may be
damaged.
Flush with water, remove affected clothing. Cover burns INT-3-1-14
with a sterile dressing then get medical help.
5-3-4-3_1
3 - 10 9803/4170-12 3 - 10
Routine Maintenance
Health and Safety
!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
!MCAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12
!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8
3 - 11 9803/4170-12 3 - 11
Routine Maintenance
Service Schedules
Service Schedules
A badly maintained machine is a danger to the operator Apart from the daily jobs, the schedules are based on
and the people working around him. Make sure that the machine running hours. Keep a regular check on the
regular maintenance and lubrication jobs listed in the hourmeter readings to correctly gauge service intervals.
service schedules are done to keep the machine in a safe Do not use a machine which is due for a service. Make
and efficient working condition. sure any defects found during the regular maintenance
checks are rectified immediately.
!MWARNING
Calendar equivalents:
Maintenance
Maintenance must be done by suitably qualified Every 10 Hours = Daily
personnel. Before attempting any maintenance work, Every 50 Hours = Weekly
make sure the machine is safe. Park on level ground.
Every 500 Hours = Six Months
If it is necessary to work with the loader arms raised,
then the loader arm safety strut must be fitted as Every 1000 Hours = Yearly
shown in Loader Arm Safety Strut in MAINTENANCE Every 2000 Hours = 2 Years
section.
Every 6000 Hours = 6 Years
2-3-1-1
Pre-start Cold Checks, Service Points and Operation 10 100 250 As 500 1000 2000
Fluid Levels Hr(1) Hr(2) Hr and Hr Hr Hr
When
ENGINE
Oil Level - Check
Oil and Filter - Change {
Oil and Filter (Tier 2 Engines)(3) - Change
Air Cleaner Outer Element - Change
Air Cleaner Inner Element (Every 3rd Outer - Change
Element)
Fuel Filter - Drain
Fuel Filter - Change {
Coolant Level - Check
Antifreeze Strength - Check {
Coolant - Change
Fuel Sedimenter - Drain
Fan Belt Tension/Condition - Check {
Valve Clearances (412S AB Build/414S YB - Check and Adjust
Build)(4)
Valve Clearances (412S AM Build/414S YH - Check and Adjust
Build)(4)
Engine Mount Security - Check {
3 - 12 9803/4170-12 3 - 12
Routine Maintenance
Service Schedules
When
Air Compressor Belt Tension/Condition (if fitted) - Check {
TRANSMISSION AND AXLES
Transmission Oil Level - Check
Transmission Oil - Change {
Transmission Strainer/Filter - Change {
Axle(s) Oil Level - Check
Axle(s) Oil - Change
Hub Oil Levels - Check
Hub Oil - Change
Prop. Shaft and Universal joints - Grease {
Prop. Shaft Security - Check
Centre Prop. Shaft Slide - Grease {
Axle Breather(s) - Clean {
Tyre Pressures and Condition - Check
Wheel Nut Security - Check {
Axle Mount Security - Check {
Transmission Mount Security - Check {
Parking Brake Operation - Check and Adjust
HYDRAULICS
Oil Level - Check
Oil Filter - Change {
Oil - Sample
Oil - Change
Suction Strainer - Clean
Servo Filter - Change {
Hoses & Pipework - Damage or Leaks - Check
Hydraulic Filler Cap - Change
ELECTRICS
Instrument Panel Operation - Check {
Wiring for Chaffing - Check {
Battery Terminals for Condition and Tightness - Check {
3 - 13 9803/4170-12 3 - 13
Routine Maintenance
Service Schedules
When
Battery Charge Condition - Check {
BODY AND FRAMEWORK
Loader End Pivots - Grease
Quickhitch Locking Pins (5) - Grease
All Hinges - Grease {
Lower Centre Pivot - Grease
Steer Ram Pivots - Grease
Upper Centre Pivot - Grease
Machine Condition Generally - Check {
CAB
Windscreen Washer Fluid Level - Fill
Cab Heater Intake Filter - Clean
Cab Recirculation Filter - Clean
ROPS/FOPS Structures - Check
Seat Belt Security and Condition - Check
(1) Operations must be carried out at the end of each set period, ie. The 10 Hour operations must be carried out after every
10 hours.
(2) 100 Hour operations marked with a symbol are carried out at the Initial 100 Hour Service ONLY.
(3) Tier 2 Engines: 412S (RJ build) from Serial No. 535650; 414S from Serial No. 537400 (BTAA 5.9-C / SO18487) 416S
from Serial No.543250 (BTAA 5.9-C / SO18487)
(4) 412S AM Build from Machine Serial Number 535353, 414S YH Build from Machine Serial Number 537161
(5) When operating in arduous conditions, grease and operate the locking pins every 10 hours.
Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
ENGINE
Idle Speed - Check and Adjust {
Torque Converter Stall Speed - Check {
Combined Stall Speed - Check
Max. No Load Speed - Check and Adjust {
Throttle System and Control Cable - Check {
Operation of Stop Control/E.S.O.S. - Check {
Exhaust Smoke - Check {
3 - 14 9803/4170-12 3 - 14
Routine Maintenance
Service Schedules
When
Fuel System For Leaks and Contamination - Check {
Exhaust System Security - Check {
Air Inlet System Security - Check {
Coolant System for Leaks - Check {
TRANSMISSION AND AXLES
Clutch Pack Pressures - Check {
Clutch Disconnect/Dump Button - Check {
Clutch Pack Calibration (AEB) - Check {
Speed Change and Selection - Check {
Forward/Reverse Selection/Operation - Check {
Neutral Start Operation - Check {
Reverse Alarm (if fitted) - Check {
Oil Cooler and Pipework - Check {
HYDRAULICS
MRV Pressure - Check and Adjust {
Steer Circuit MRV Pressure - Check and Adjust {
ARV Pressure - Check and Adjust
Operation of All Services - Check {
Hoses for Damage and Leaks - Check
Pipework for Damage and Leaks - Check
Piston Rods and Gland Seals - Check
BRAKES
Foot Brake Operation and Balance - Check {
Parking Brake - Check and Adjust {
ELECTRICS
Starter Motor - Check {
Alternator - Check {
Gauges and Warning Lights - Check {
Proximity Sensor Function - Check {
Cab Switches - Check {
Wiper Motors - Check {
3 - 15 9803/4170-12 3 - 15
Routine Maintenance
Service Schedules
When
Heater - Check
Other (give details) - Check
CAB
Glazing for Correct Fit - Check {
Doors and Hinges - Check {
Tool Kit and Handbook - Check {
Locks and Keys - Check {
Seat/Seat Belts - Check {
PAINTWORK
Condition - Check
ATTACHMENTS
Attachment Circuit Pressures - Check {
Operation - Check {
REGISTRATION/CERTIFICATION
Form 2530 (F91) (UK Requirement) - Lift - Check
Form 2531 (F96/F97) (UK Requirement) - Check
SWL Stickers (UK) - Renew as
Required
(1) Operations must be carried out at the end of each set period, ie. The 10 Hour operations must be carried out after every
10 hours.
(2) 100 Hour operations marked with a symbol are carried out at the Initial 100 Hour Service ONLY.
Table 5. Key
Regular Maintenance Check
{ Initial 100 Hour Check Only
3 - 16 9803/4170-12 3 - 16
Routine Maintenance
Greasing
Greasing
!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground and lower the
attachments, (If it is necessary to work with the loader
arms raised, then the loader arm safety strut must be
fitted). See Loader Arm Safety Strut in MAINTENANCE
section. Engage the park brake, put the transmission
in neutral and stop the engine. Block both sides of all
four wheels. If you are working near the articulation
danger zone, fit the articulation safety lock. See
Articulation Lock in MAINTENANCE section.
4-3-2-4_1
Bucket Pivot Points

Total of 4 grease points (1-1 to 1-4)
Loader Arm Pivot Points

Total of 20 grease points. (1-5 to 1-24)
For interval see K Service Schedules ( T 3-12)
The machine must be greased regularly to keep it working

efficiently. Regular greasing will also increase the
machine's working life.
Grease should be applied with a grease gun, normally two

strokes of the gun should be sufficient. Stop the greasing
procedure when fresh grease appears at the joint. Use the
recommended grease. See K Lubricants and
Capacities - Pre-Smoothshift Transmission ( T 3-1).
In the following illustrations, the grease points are

numbered. Count off the grease points as you apply
grease to each one. Refit the dust caps after greasing.
3 - 17 9803/4170-12 3 - 17
Routine Maintenance
Greasing
Fig 1.
3 - 18 9803/4170-12 3 - 18
Routine Maintenance
Greasing
Centre Pivot and Steering Ram Quickhitch Locking Pins

Total of 7 grease points Attachments must be removed in order to grease the
locking pins.
For interval see K Service Schedules ( T 3-12)
Total of 2 grease points
!MDANGER
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation
danger zone.
If the articulation lock is not fitted you could be

crushed between the two parts of the chassis.
GEN-3-1_1
Fig 3.
Note: When working in arduous conditions, grease and

operate the locking pins every 10 hours.
Fig 2.
3 - 19 9803/4170-12 3 - 19
Routine Maintenance
Greasing
Propshafts !MWARNING
Total of 7 grease points Make the machine safe before working underneath it.
Park the machine on level ground and lower the
Note: Centre Propshaft Sliding Spline - grease point 4-1. attachments, (If it is necessary to work with the loader
arms raised, then the loader arm safety strut must be
For interval see K Service Schedules ( T 3-12) fitted). See Loader Arm Safety Strut in MAINTENANCE
section. Engage the park brake, put the transmission
in neutral and stop the engine. Block both sides of all
four wheels. If you are working near the articulation
danger zone, fit the articulation safety lock. See
Articulation Lock in MAINTENANCE section.
4-3-2-4_1
Fig 4.
3 - 20 9803/4170-12 3 - 20
Routine Maintenance
Loader Arm Safety Strut
Loader Arm Safety Strut
Installing the Loader Arm Safety Strut Removing the Loader Arm Safety Strut
!MWARNING !MWARNING
Never walk or work under raised equipment unless it You could be killed or injured if the loader control is
is supported by a mechanical device. Equipment accidentally operated. Make sure no-one comes near
which is supported only by a hydraulic device can the machine while you remove the safety strut.
drop and injure you if the hydraulic system fails or if 2-3-1-3
the control is operated (even with the engine stopped).
13-2-3-7 1 Make sure the parking brake is on, and that the
transmission is in neutral.
!MWARNING 2 Raise the loader arm to take the weight off the safety
You could be killed or seriously injured if the loader strut 5-A. Stop the engine.
control is accidentally operated. Make sure that no-
one goes near the machine whilst you fit the safety 3 Remove the strut:
strut.
16-3-1-5 a Release securing strap 5-B.
1 Empty the bucket and raise the loader arm enough to b Remove safety strut.
fit the safety strut 5-A.
c Return the safety strut to its stowage position.
2 Apply the parking brake, put the transmission in
neutral and stop the engine.
3 Fit the strut:
a Remove the strut from its stowage position.
b Place the strut around the ram.
c Secure the strut into position using strap 5-B.
4 Start the engine.
5 Slowly lower the loader arm onto the safety strut.

Stop the movement immediately the weight of the
arm is supported by the strut.
Note: Extreme care must be taken when lowering the

loader arm onto the safety strut. 'Feather' the lever to lower Fig 5.
the loader arm slowly.
3 - 21 9803/4170-12 3 - 21
Routine Maintenance
Articulation Lock
Articulation Lock
Installing the Articulation Lock
!MDANGER
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation
danger zone.
If the articulation lock is not fitted you could be

crushed between the two parts of the chassis.
GEN-3-1_1
On the Wheeled Loader, the articulation safety lock is

stowed on the machine as shown. The articulation lock is
fitted with the machine in a 'straight ahead' position.
1 Steer the machine to bring the front and rear wheels

in a straight line.

neutral.
3 Remove pin 6-A and pivot articulation lock into

locking position, replace pin 6-A at position 6-1. If pin
will not fit, turn steering wheel slightly to align hole.
4 Stop the engine.
3 - 22 9803/4170-12 3 - 22
Routine Maintenance
Articulation Lock
Removing the Articulation Lock 1 Remove pin 6-A.
!MWARNING 2 Return the articulation lock to its stowage position as

shown.
Always make sure the articulation safety lock has
been removed before attempting to drive the machine. 3 Lock the articulation lock into its stowage position by
The machine cannot be steered with the articulation replacing pin at position 6-2 as shown.
lock fitted.
16-3-1-4
Fig 6.
3 - 23 9803/4170-12 3 - 23
Routine Maintenance
Hydraulic System
Hydraulic System
!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
Checking the Fluid Level

neutral, lower the shovel/attachment to the ground.
Make sure it is flat on the ground. Stop the engine.
2 Look at the fluid level in the plastic tube 7-A. The level
Fig 8.
should be mid way between the two marks on the
tube. Later machines are fitted with a sight glass. The
level should be visible in the sight glass. !MCAUTION
3 If necessary, top up with hydraulic fluid. If the fluid is cloudy, then water or air has
contaminated the system. This could damage the
4 Open the right side engine cover. Open filler cap 8-B. hydraulic pump. Contact your JCB Distributor
immediately.
5 Top up the system with hydraulic fluid. See 12-5-1-4
K Lubricants and Capacities - Pre-Smoothshift
Transmission ( T 3-1).
6 Refit filler cap 8-B. Make sure it is secure. Close and

lock the engine cover.
Fig 7.
3 - 24 9803/4170-12 3 - 24
Routine Maintenance
Hydraulic System
Changing the Filter Element
!MWARNING
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1
1 Open the right side engine cover.
2 Remove hydraulic tank cap.
3 Unscrew and remove nuts 9-A, cover plate 9-D and

seal 9-E.
4 Pull out the complete element assembly 9-F and the

seal.
Fig 9.
5 Remove the nut and spring 9-K. Remove the filter
element 9-L from the spindle and clean magnets 9-J.
6 Fit the new element 9-L and the new seals 9-G and 9-
H.
7 Replace the cover plate 9-D and tighten nuts 9-A to 7

Nm (5 lbf ft).
8 Top up the system with hydraulic fluid. See

K Lubricants and Capacities - Pre-Smoothshift
Transmission ( T 3-1).
9 Refit filler cap. Make sure it is secure. Close and lock

the engine cover.
3 - 25 9803/4170-12 3 - 25
Routine Maintenance
Transmission
Transmission
Checking the Oil Level

1 Park the machine on level ground.

neutral.
3 Open the left side engine cover. Remove, wipe and

replace the dipstick 10-A.
Note: Turn `T' handle 10-D two full turns anti-clockwise to

release the dipstick. Turn `T' handle 10-D two full turns
clockwise to fasten in position. Check that the dipstick is
secure.
4 Make sure the oil is at the correct mark on the

dipstick.
5 If necessary, add recommended oil at dipstick/filler Fig 10. 412S (Pre-Smoothshift Transmission)
point 10-A.
The dipstick is marked as follows:
HOT - When the engine/transmission is at working

temperature.
Note: The transmission may overheat if the oil level is

above the HOT mark.
COLD - When the engine has been started but has

not warmed up.
6 Close and lock the engine cover.
Fig 11. 414S/416S (Pre-Smoothshift Transmission)
3 - 26 9803/4170-12 3 - 26
Routine Maintenance
Transmission
Fig 12. 412S (Smoothshift Transmission)
Fig 13. 414S/416S (Smoothshift Transmission)
3 - 27 9803/4170-12 3 - 27
Routine Maintenance
Transmission
Changing the Oil and Filter (412S)
!MWARNING

GEN-4-1_1
!MWARNING
When the filter is removed, oil will gush out. Keep to
one side when you remove the filter.
4-3-4-3 Fig 14.
1 Drain the oil and remove the filter:
a Place a container that can hold 17 litres (3.75 gal.)

beneath the machine. (To catch the oil).
b Remove bolts 14-D.
c Pull out filter 14-E and its 'O' ring 14-F and remove
'O' ring 14-G.
2 Fit the new filter and 'O' ring assembly 14-E and 14-F
and a new 'O' ring 14-G. Smear the 'O' rings with
clean transmission fluid before fitting.
3 Torque tighten bolts to 23 Nm (17 lbf ft).
4 Fill the system with new oil at dipstick/filler point 15-A.
Note: Do not fill past the top mark on the dipstick. Fig 15.
3 - 28 9803/4170-12 3 - 28
Routine Maintenance
Transmission
Changing the Oil and Filter (414S/416S)
!MWARNING

GEN-4-1_1
1 Place a container that can hold 20 litres (4.5 gal.)

beneath the machine. (To catch the oil).
2 Remove dipstick 16-A and drain plug 17-B. Allow oil

to drain into the container.
3 Clean and refit plug 17-B
4 Unscrew and discard filter 17-C. Clean the mounting

face and lubricate the seal 17-D on the new filter with
clean transmission fluid.
Note: On later 414S and 416S machines, the oil filter is

fitted remotely on the right-hand side of the engine.
5 Fit the new filter - hand tight only.
Note: Do not fill past the top mark on the dipstick.
Fig 17.
Fig 16.
3 - 29 9803/4170-12 3 - 29
Routine Maintenance
Transmission
Changing the Oil and Filter
!MWARNING

GEN-4-1_1
1 Place a suitable container beneath the transmission

(to catch the oil).
2 Remove the dipstick 18-A and drain plug 19-B.
3 Drain the oil. Clean and refit drain plug 19-B.
4 Unscrew and discard filter 19-C. Clean the mounting

face and lubricate the seal on the new filter with clean
torque converter fluid. Fig 19. 412S
5 Fit the new filter 19-C hand tight only.
Note: Do not fill past the top mark on the dipstick.
Fig 18. 412S
3 - 30 9803/4170-12 3 - 30
Routine Maintenance
Transmission
Fig 20. 414S/416S
Fig 21. 414S/416S
3 - 31 9803/4170-12 3 - 31
Routine Maintenance
Front and Rear Axles
Checking the Oil Level
!MWARNING

GEN-4-1_1
!MCAUTION
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil
in the axle will be given.
16-3-5-3
1 Clean the area around fill/level plug 22-A.
2 Remove fill/level plug 22-A and its seal, oil should be

level with the bottom of the hole.
3 Top up with the recommended oil if necessary.
4 Clean and refit fill/level plug 22-A and its seal. Tighten
to 85 Nm (60 lbf ft).
Fig 22.
3 - 32 9803/4170-12 3 - 32
Routine Maintenance
Changing the Oil
!MWARNING

GEN-4-1_1
1 Make sure both fill/drain plugs 23-C are at the bottom,

as shown at 23-D.
2 Remove plugs 22-A, 22-B and 23-C and their seals.

Drain the oil into suitable containers. Allow the oil to
drain fully.
!MCAUTION Fig 23.
Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the plug.
2-3-4-2
3 Clean and refit drain plug 22-B and its seal. Plug 22-
B is magnetic, make sure all debris is removed.
Tighten to 85 Nm (60 lbf ft).
!MCAUTION
There will be no oil in the hub when the machine is
driven forward. Only drive the machine forward one
quarter revolution of the wheel. Do not drive the
machine more than is necessary.
4-3-5-1
4 Drive the machine slowly forward to bring the OIL

LEVEL mark on the hubs into the horizontal position,
as shown at 24-E.
5 Fill the axle with the recommended oil through fill/

level plug 22-A, until oil starts to dribble from both hub Fig 24.
fill/drain points 24-C.
6 Clean and refit fill/level plug 22-A and both fill/drain

plugs 24-C and their seals. Tighten to 85 Nm (60 lbf
ft).
3 - 33 9803/4170-12 3 - 33
Routine Maintenance
Engine
Engine
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 working underneath it.
sure the engine is cool before doing this job. Park the machine on level ground, lower the
2-3-3-2 attachments to the ground. Apply the park brake, put
Note: The illustration below shows the layout for 412S both sides of all four wheels.
machines, however, the dipstick and filler points are in
similar positions on 414S machines. Disconnect the battery, to prevent the engine being
1 Park the machine on level ground and lower the GEN-4-1_1
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 Note: 414S machines are fitted with dual filter canisters.
the dipstick 25-A. Repeat the procedure for the second filter.
5 If necessary, add the recommended oil through the 1 Do Steps 1 to 3 of K Checking the Oil
filler point 25-B. See K Lubricants and Capacities - Level ( T 3-26).
Pre-Smoothshift Transmission ( T 3-1).
2 Place a suitable container beneath the drain plug 26-
6 Make sure the filler cap and the dipstick are secure. A (to catch the oil).
Close and lock the engine cover.
Fig 26.
Fig 25. 3 Remove drain plug and its 'O' ring and drain the oil
from the sump. Renew the 'O' ring.
3 - 34 9803/4170-12 3 - 34
Routine Maintenance
Engine
Note: Some 414S machines are fitted with a self-sealing
drain plug. Use a self-sealing drain kit with this type.
4 Clean and refit the drain plug and its 'O' ring and
tighten the drain plug to 34 Nm (25 lbf ft). DO NOT
OVERTIGHTEN.
5 Unscrew the filter canister 27-C. Remember that it will

be full of oil.
6 Clean filter head 27-D.
7 Add clean engine oil to the new filter canister. Allow

time for the oil to pass through the filter element.
8 Smear the seal 27-E on the new filter canister with

clean engine oil.
9 Screw in the new filter canister - hand tight only. Fig 27.
10 Fill the engine with the recommended oil, to the MAX

mark on the dipstick, through the filler point. Wipe off
any spilt oil, refit the filler cap and make sure it is
secure. Close the engine cover.
11 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
warning light is extinguished.
Note: To make sure the engine will not start, remove the
engine shut-off solenoid fuse. See Section C, Technical
Data.
12 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has
cooled, check the oil level.
3 - 35 9803/4170-12 3 - 35
Routine Maintenance
Engine
Checking the Oil Level (412S from Serial Changing the Oil and Filter (412S from
No. 535650) Serial No. 535650)
!MCAUTION !MWARNING
Hot oil and engine components can burn you. Make Make the machine safe before working underneath it.
sure the engine is cool before doing this job. Park the machine on level ground, lower the
2-3-3-2 attachments to the ground. Apply the park brake, put
Note: The illustration below shows the layout for 412S both sides of all four wheels.
machines from Serial No. 535650.
1 Park the machine on level ground and lower the started while you are beneath the machine.
attachments to the ground. GEN-4-1_1

remove the starter key.
!MCAUTION
Hot oil and engine components can burn you. Make
3 Open the right side engine cover. sure the engine is cool before doing this job.
2-3-3-2
4 Check that the oil level is between the two marks on
the dipstick 28-1. 1 Do Steps 1 to 3 of K Checking the Oil
Level ( T 3-26).
5 If necessary, add the recommended oil through the
filler point 28-2. See K Lubricants and Capacities - 2 Place a suitable container beneath the drain plug (to
Pre-Smoothshift Transmission ( T 3-1). catch the oil).
6 Make sure the filler cap and the dipstick are secure. Note: 412S machines From Serial No. 535650 are fitted
Close and lock the engine cover. with a self-sealing drain plug. Use a self-sealing drain kit
with this type.
3 Remove the self sealing drain plug outer threaded

cover.
4 Fit the self sealing drain kit threaded union (with

attached drain pipe) and drain sump oil into a suitable
container.
5 Remove the self seal drain kit, clean and refit the
outer cover. (Do not over tighten the cover).
6 Unscrew the filter canister 29-1. Remember that it will

be full of oil.
7 Clean filter head 29-2.
8 Add clean engine oil to the new filter canister. Allow

9 Smear seal 29-3 on the new filter canister with clean

engine oil.
Fig 28.
3 - 36 9803/4170-12 3 - 36
Routine Maintenance
Engine
10 Screw in the new filter canister - hand tight only.
11 Fill the engine with the recommended oil, to the MAX

mark on the dipstick, through the filler point. Wipe off
secure. Close the engine cover.
engine shut-off solenoid fuse. See Section C, Technical
Data..

Fig 29.
3 - 37 9803/4170-12 3 - 37
Routine Maintenance
Engine
Checking the Oil Level (414S from Serial

No. 537400 & 416S from Serial No.
543250)
!MCAUTION
2-3-3-2
1 Park the machine on level ground and lower the


4 Check that the oil level is between the two marks on

the dipstick 30-A.
5 If necessary, add the recommended oil through the

filler point 30-B. See K Lubricants and Capacities -
Pre-Smoothshift Transmission ( T 3-1).
Fig 30.
6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.
3 - 38 9803/4170-12 3 - 38
Routine Maintenance
Engine
Changing the Oil and Filter (414S from

Serial No. 537400 & 416S from Serial No.
543250)
!MWARNING

GEN-4-1_1
!MCAUTION
2-3-3-2
1 Park the machine on level ground and lower the


3 Open the left side engine cover.
4 Place a suitable container beneath the drain plug (to

catch the oil).
Fig 31.
5 Remove the self sealing drain plug outer threaded
cover 31-A 10 Add clean engine oil to the new filter canister. Allow
6 Fit the self sealing drain kit threaded union (with
attached drain pipe) and drain the sump oil. 11 Smear the seal 33-E on the new filter canister with
clean engine oil.
7 Remove the self seal drain kit, clean and refit the
outer cover. (Do not over tighten the cover.) 12 Screw in the new filter canister until it just contacts the
filter head.
8 Clean the area around the filter head. Unscrew the
filter canister 33-C. Remember that it will be full of oil. 13 Turn the filter a further 3/4 of a turn.
9 Clean filter head 33-D. Make sure that the `O' ring is 14 Fill the engine with the recommended oil, to the MAX
removed. mark on the dipstick, through the filler point. Wipe off
secure. Close the engine covers.
3 - 39 9803/4170-12 3 - 39
Routine Maintenance
Engine
engine shut-off solenoid fuse (see Section C, Technical
Data.).

Fig 32.
Fig 33.
3 - 40 9803/4170-12 3 - 40
Routine Maintenance
Fuel System
Fuel System
Types of Fuel – ASTM D975-91 Class 1-1DA.

T3-007_2 – JP7, MIL T38219 XF63.
Use good quality diesel fuel to get the correct power and – NATO F63.
performance from your engine.
Sulphur Content
Recommended Fuel Specification
– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. !MCAUTION

– BS2869 Class A2. A combination of water and sulphur will have a
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US corrosive chemical effect on fuel injection equipment.
DFA. It is essential that water is eradicated from the fuel
system when high sulphur fuels are used.
– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade
ENG-3-2
3.
High sulphur content can cause engine wear. (High
Note: Where low sulphur/low aromatic fuels are used it is
sulphur fuel is not normally found in North America,
important that lubricity additives are used. The additives
Europe or Australia.) If you have to use high sulphur fuel
listed below are advertised as being suitable for bringing
you must change the engine oil more frequently.
the lubricity levels of kerosene/low sulphur fuels up to
those of diesel fuels. They have not been tested or
Table 6.
approved by the engine manufacturer. They should be
added by your fuel supplier who should understand the Percentage of sulphur in Oil Change Interval
concentration level necessary. the fuel (%)
Less than 0.5 Normal
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), 0.5 to 1.0 0.75 of normal
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels. More than 1.0 0.50 of normal
2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) Aviation Kerosene Fuels
250 ppm.
Note: Aviation kerosene fuels are not approved and their
3 Paradyne 7505 (from Infineum). Dosage 500 ppm use may cause damage to components. Warranty will not
(0.05%). be allowed on any component where damage is found to
have been caused by the use of aviation kerosene.
!MCAUTION Low Temperature Fuels
Consult your fuel supplier or JCB distributor about the
suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation
GEN-9-2 at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
Acceptable Fuel Specification low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter.)
!MCAUTION Fatty Acid Methyl Ester Fuels as a Replacement
The fuel specification below is acceptable, however for diesel Fuels
this fuel may reduce the life of the fuel injection
equipment. The use of this fuel may also affect the Fuel resources such as Rape Methyl Ester and Soybean
engine performance. Methyl ester, collectively known as Fatty Acid Methyl
GEN-9-3
3 - 41 9803/4170-12 3 - 41
Routine Maintenance
Fuel System
Esters are being used as alternatives and extenders for
mineral oil.
Fatty Acid Methyl Esters must conform to certain

standards to be of acceptable quality, just as mineral oils
do at present.
Consult your JCB distributor for advice about the use of

Fatty Acid Methyl Ester fuels, as improper application may
impair engine performance.
!MWARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from
the fuel system. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. There could be a fire and injury if you
do not follow these precautions.
INT-3-2-2_1
Petrol
!MWARNING
Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6
3 - 42 9803/4170-12 3 - 42
Routine Maintenance
Fuel System
Draining the Fuel Filter

Note: 414S machines are fitted with dual filters. Repeat
the procedure for the second filter.

3 Drain off any water in the bowl 34-B by turning tap 34-
A.
!MCAUTION
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11
Fig 34.
3 - 43 9803/4170-12 3 - 43
Routine Maintenance
Fuel System
Changing the Fuel Filter Element Cleaning the Sedimenter Bowl

1 Apply the parking brake, put the transmission in If bowl 35-B contains sediment carry out the following:-
1 Hold the bowl 35-B and unscrew nut 35C.
2 Remove the bowl, and wash in clean fuel.
3 Hold bowl 34-B and unscrew bolt 34-C, remove bowl
and filter element 34-E. 3 Refit the bowl. Make sure the gasket is in good
condition and positioned correctly.
4 Inspect seals 34-D and renew if damaged.
4 Re-tighten nut 35-C, taking care not to over-tighten.
5 Fit new element 34-E, sealing rings 34-D and bowl
34-B. Make sure seals 34-D are seated correctly. 5 Bleed the fuel system. See K Bleeding the
System ( T 3-45).
6 Tighten bolt 34-C.
7 Bleed the fuel system. See K Bleeding the

System ( T 3-45).
Draining the Sedimenter Bowl

3 Drain off any water in the bowl by turning tap 35-A

and slackening screw 35-D.
4 Tighten screw 35-D and make sure tap 35-A is turned

off and secure.
5 Close and lock the engine cover. Fig 35.
!MCAUTION
2-3-3-11
3 - 44 9803/4170-12 3 - 44
Routine Maintenance
Fuel System
Bleeding the System
!MCAUTION
2-3-3-11
If the engine fails to start, misfires or if any part of the fuel

system has been disconnected or emptied, bleed the
system as follows:

3 Make sure that there is enough fuel in the fuel tank.
4 Turn the starter key to the IGN position.Operate the

fuel lift pump priming lever 36-X slowly for about two
minutes.Turn the starter key fully clockwise to the HS
position until the engine starts.
Note: If the engine runs smoothly for a short time and then
begins to run roughly or stops, check again for air in the
fuel system.
Fig 36.
3 - 45 9803/4170-12 3 - 45
Routine Maintenance
Fuel System
Draining the Fuel Filter (Spin-on)

3 Drain off any water in the bowl 37-A by turning tap 37-
B.
4 Repeat for second filter.
!MCAUTION
2-3-3-11
Changing the Fuel Filter Element (Spin-

on)
3 Unscrew the filter element 37-A, the element is hand

tight but may require a strap wrench to remove. The
filter will be full of fuel.
4 Repeat for second filter.To assist with bleeding fill the

filter element with fuel before fitting. Install the filter
element 37-A, hand tight only. Check for leaks.

Fig 37.
System ( T 3-45).
3 - 46 9803/4170-12 3 - 46
Routine Maintenance
Fuel System
Fuel Lift Pump

An improved fuel lift pump has been introduced for use on
JCB four-cylinder 1000 Series diesel engines. The new
pump is a one piece assembly and cannot be dismantled.
The new pump is interchangeable with the earlier pump.
The procedure to remove and fit the new pump has not
changed, see Engine Service Manual. Remove and clean
fuel inlet strainer 38-2 when suspected blocked ie. low on
power, difficult to start, fuel tank contamination.
Cleaning the Strainer
1 Allow the engine to cool. Remove the fuel filler cap to

vent the system and reduce loss of fuel. Disconnect
the fuel inlet pipe to the lift pump.
2 Unscrew the fuel filter 38-A. Remove strainer 38-2

and O-ring 38-3.
3 Clean the strainer in clean diesel fluid and dry with

low pressure compressed air. Renew the strainer and
O-ring if damaged.
4 Fit the strainer into the fuel inlet connection. Fit the
inlet connector 38-A and tighten to 20Nm (15 lbf ft).
Fit the fuel inlet pipe carefully to prevent damage to
the strainer, and tighten the union nut. Fig 38.
Important: The fuel strainer can be damaged and fuel flow

can be restricted if the fuel pipe is inserted too far into the
inlet connection. This should be checked if a fuel restriction
is suspected.
Make sure the olive on the fuel inlet pipe is in good

condition and forms an effective seal. Renew the
olive or pipe if necessary to prevent air entering the
fuel system.
5 Fit the tank cap and prime the fuel system. Start the
engine and check for fuel leakage.
3 - 47 9803/4170-12 3 - 47
Routine Maintenance
Fuel System
Draining the Fuel Filter (412S from Serial

No. 535650)
!MCAUTION
The engine no longer carries a mechanical lift pump.
The fuel system now incorporates an electric pump
built into the filter head. As this pump is fed from the
machine's ignition circuit, it is important that the
ignition is turned off whenever the fuel system is
being worked on.
0104
2 Open the engine canopy.
3 Drain off any water in the filter assembly 39-A by

turning tap 39-B.
4 Make sure tap 39-B is turned off and secure.
!MCAUTION
Fig 39.

2-3-3-11
3 - 48 9803/4170-12 3 - 48
Routine Maintenance
Fuel System
Changing the Fuel Filter (412S from

Serial No. 535650)
!MCAUTION
The fuel system now incorporates an electric pump
being worked on.
0104
3 Grasp the filter bowl 40-C and unscrew from the filter
housing 40-D.
4 To remove the element from the bowl. Push

downwards on the element and turn it one quarter of
a turn anti clockwise. The element can now be lifted
from the bowl Fig 40.
5 Wash out the bowl with clean fuel.
6 Replace the bowl sealing ring 41-E. (A new sealing

ring must be fitted whenever the bowl is separated
from the filter housing).
7 Insert a new element into the bowl. Turn the element

until it can be felt to drop onto its seat. (It will not be
possible using a gentle twisting motion to rotate the
filter once it is corrctly on its seat). Push down on the
element and turn it a quarter of a turn clockwise 41-F.
(The filter should now be held securely in place in the
bowl).
8 Lightly lubricate the filter bowl sealing ring 41-E. Re

screw the filter bowl back onto the housing. Tighten
the filter bowl by hand only.
Note: The thread holding the filter element and bowl to the
housing is cut internally into the element material. Over
tightening can damage this thread.
Fig 41.
System ( T 3-45).
10 Close the engine canopy.
3 - 49 9803/4170-12 3 - 49
Routine Maintenance
Fuel System
Draining the Fuel Sedimenter (412S from Cleaning the Sedimenter Bowl
Serial No. 535650)
If bowl 42-B contains sediment carry out the following:-
1 Open the engine canopy and locate sedimenter .
1 Hold the bowl 42-B and unscrew nut 42-C.
!MCAUTION 2 Remove the bowl, and wash in clean fuel.

The fuel system now incorporates an electric pump 3 Refit the bowl. Make sure the gasket is in good
built into the filter head. As this pump is fed from the condition and positioned correctly.
ignition is turned off whenever the fuel system is 4 Re-tighten nut 42-C, taking care not to over-tighten.
being worked on.
0104
System ( T 3-45).
2 Drain off any water in the bowl by turning tap 42-A.
3 Make sure tap 42-A is turned off and secure.
!MCAUTION
2-3-3-11
Fig 42.
3 - 50 9803/4170-12 3 - 50
Routine Maintenance
Fuel System
Draining the Fuel Sedimenter (412S from Changing the Sedimenter Filter (412S
Serial No. 535705) from Serial No. 535705)
1 Open the engine canopy and locate sedimenter . Note: The fuel sedimenter assembly fitted to the TM300
now incorporates a paper and gauze filter element.
!MCAUTION 1 Hold the bolt 43-C and unscrew the bowl 43-B.
The fuel system now incorporates an electric pump 2 Remove the bowl
machine's ignition circuit, it is important that the 3 Remove the filter element (43-D).
being worked on. 4 Wash out the bowl with clean fuel.
0104
5 Fit a new filter element.
2 Drain off any water in the bowl by turning tap 43-A.
6 Refit the bowl. Make sure the gasket is in good
3 Make sure tap 43-A is turned off and secure. condition and positioned correctly.
!MCAUTION Note: It is most important that the bolt 43-C is held while
the bowl is screwed onto it and that the bowl is not over
Running the engine with air in the system could tightened.
the system must be bled to remove any air. 7 Screw the filter bowl onto the bolt 43-C until the seal
2-3-3-11 contacts the filter head. Tighten the bowl by hand a
further 1/4 of a turn.

System ( T 3-45).
9 Run the engine and check for leaks.
Fig 43.
3 - 51 9803/4170-12 3 - 51
Routine Maintenance
Fuel System
Bleeding the Fuel System (412S from

Serial No. 535650)
!MCAUTION
2-3-3-11
If the fuel system has been disturbed by changing the fuel

filter or if the fuel injection pump has been drained or
replaced, the following procedure should be followed.
2 Make sure that there is enough fuel in the fuel tank.
3 Operate the electronic lift pump and the fuel injection

pump solenoid for three minutes. (To activate the
solenoid and lift pump, turn the ignition key to the on
position).
4 Turn the starter key fully clockwise to the start

position. The engine should then fire immediately
upon cranking.
3 - 52 9803/4170-12 3 - 52
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.

JCB 412S WHEELED LOADER Service Repair Manual SN 535000 PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

JCB 412S WHEELED LOADER Service Repair Manual SN 535000 PDF

Загружено:

Авторское право:

Доступные форматы

Service Manual

Wheeled Loading Shovel - 412S, 414S,

Page left intentionally blank

1-0 9803/4170-10 1-0

Contents Page No.

Identifying your Machine

Contents Page No.

Section contents, technical data, circuit descriptions,

1-1 9803/4170-10 1-1

Identifying your Machine

Explanation of Vehicle Identification

1 World Manufacturer Identification, SLP = JCB

2 Machine Model, 412S0 = 412S

3 Year of Manufacture S, (P = 1993, R = 1994, S = Fig 2. 412S Machines

4 Manufacturing Location (E = England)

5 Machine Serial Number (0527001)

The serial number of each major unit is also stamped on

1-2 9803/4170-10 1-2

Fig 3. 414S Machines

Typical Engine Identification Number

a AA = 4 cylinder naturally aspirated

4 Engine Sequence Number Fig 4. 412S Machines

1-3 9803/4170-10 1-3

Fig 5. 414S Machines

1-4 9803/4170-10 1-4

M3 (3) 1.2 0.12 0.9

1-5 9803/4170-10 1-5

JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)

Note: All adapters, elbows and hoses should be tightened

1-6 9803/4170-10 1-6

Note: All adapters, elbows and hoses should be tightened

1-7 9803/4170-10 1-7

Part Description Tool Detail

1-8 9803/4170-10 1-8

Tool Detail Reference Section B - Body and Framework

Note: essential for preparing new glass prior to

Fig 1. Fig 3. 892/00842

1-9 9803/4170-10 1-9

Fig 12. 825/99849

Fig 10. 892/00849

Fig 13. 825/99850

Fig 11. 892/00844

Fig 14. Cab Prop

Manufacture from mild steel.

Tube wall and plate minimum thickness must be 3 mm.

Numerical List Section C - Electrics

Part Description Tool Detail

Tool Detail Reference Section C - Electrics

Fig 16. 993/85700

Numerical List Section E - Hydraulics

Part Description Tool Detail

Part Description Tool Detail

Part Description Tool Detail

Tool Detail Reference Section E- Hydraulics

816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

Fig 19. Bonded Washers

Fig 20. Flow Test Equipment

1604/0006 Adapter 3/4 in M x 3/4 M BSP

Fig 23. Pressure Test Adapters

Fig 24. Female Connectors

Fig 25. Hexagon Spanners for Ram Pistons and End

992/09300 55 mm 892/00223 Hand Pump

992/09400 65 mm 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres