Part of the JCB Repair Manuals.
An EMS warning counting down to shutdown, a ZF fault code on the dash, a loader valve service gone slow. This is the JCB service manual for the 412S, 414S and 416S wheel loaders, written for the technician working on the machine.
It covers the Perkins 1000 Series and JCB Dieselmax engines, the WG 110/160 powershift, the PD 70 and PD 90 axles, brakes, steering and the Smooth Ride System. Guessing costs money: ram seals fitted when the real fault was a kinked line, or a limited slip diff stripped twice because the plates went back in the wrong order.
Keep it on the bench, on a tablet in the cab, or on the laptop you plug in for JCBTerm.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-48 | About This Manual, Machine Identification Plates, Zinc Plated and Dacromet Fasteners, Hydraulic Connections, JCB Standard Torque Settings, Service Tools by Section |
| Care and Safety | 49-67 | Safety Check List, General, Operating and Maintenance Safety, Safety Labels and Part Numbers |
| Routine Maintenance | 68-167 | Service Schedules, Pre-Start Checks, Fluids, Lubricants and Capacities, Coolant Mixtures, Fuel, Preparing the Machine for Maintenance, Engine Oil and Filter Change |
| Attachments | 168-175 | Optional Attachments, Connecting and Disconnecting Hydraulic Hoses, Quick Release Couplings |
| Body and Framework | 176-265 | Air Conditioning Technical Data, Operation and Fault Finding, Refrigerant Charging and Leak Testing, Cooling Pack, Cab, Glazing, ROPS/FOPS Structure, Seat, Centre Pivot, Heater and Air Conditioning Controls |
| Electrics: Data, Fault Finding and Service | 266-319 | Fuses and Relays by Serial Range, Fault Finding Techniques with a Multimeter, Battery Testing, Alternator Charging Circuit, Starting Circuit, Wiring Harness Repair |
| Electrics: Schematic Circuits | 320-411 | Wiring Schematics with Component Keys for 412S, 414S and 416S by Serial Range: Primary Fuses and Ignition, Instrumentation, ZF Computer and Gearbox Controller, Engine, Wipers and Heater, Lights, Loader Auxiliaries, Earthing |
| Electrics: Harness Data | 412-573 | Wire and Harness Number Identification, Wire Numbers and Functions, Harness Drawings and Connector Identification |
| Electrics: Electronic Monitoring System | 574-629 | EMS Visual Warnings and Messages, Automatic Engine Shut Down, Log Data Download and Reset with JCB Term, Alternator, Starter Motor, LiveLink |
| Hydraulics: Data, Schematics and Valves | 630-673 | Pump and Relief Valve Data for 412S, 414S and 416S, Hydraulic Schematic Symbols, Hydraulic Schematic Circuits with Component Keys, Loader Valve Port Tables |
| Hydraulics: Circuit Descriptions, Service and Fault Finding | 674-727 | Loader Valve Circuits, Auxiliary and Main Relief Valve Operation, Unloader, Servo Control Valves, Start Up Valve, Hydraulic Contamination, Releasing Hydraulic Pressure, Pressure Testing, Smooth Ride System, Fault Finding |
| Hydraulics: Components | 728-781 | Hydraulic Pumps, Rams, Servo Control Levers and Valves, SRS Control Valve, Accumulators and Isolating Valve, Loader Valve Block |
| Transmission | 782-923 | Drive Axle Data, Stall Testing, Towing Procedure, Powershift Transmissions, Smoothshift WG 110/160 Oil Circulation, Power Flow and Test Points, Clutch and Final Drive Dismantling and Assembly |
| Axles | 924-951 | Front and Rear Axle Removal, Drive Head, Crown Wheel and Pinion Adjustment, Limited Slip Differential, Hub and Driveshaft PD 70 and PD 90, Axle Brakes Dismantling and Assembly |
| Transmission: Diagnostics and Fault Codes | 952-1017 | Transmission Test Procedure, Transmission Fault Finding, Fault Codes Wg-110/160, ZF Error Codes and Operating Modes, Control Lever Wiring |
| Brakes | 1018-1065 | Brake Circuit Descriptions, Park Brake Testing and Adjustment, Accumulator Charging, Brake Valves, Charge Valve, Brake Pedal, Bleeding the System |
| Hydraulic Steering | 1066-1085 | Steering Pump, Steering Valve Operation, Steering Shock Valve, Dismantling and Assembly |
| Engine | 1086-1103 | Engine Technical Data by Model and Serial Range, Perkins 1000 Series and JCB Dieselmax Engines, Unit Identification |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 412S, 414S, 416S | ||
| A/C binary switch - low pressure | 2.05 bar (29.8 lbf/in², 2.1 kgf/cm²) | p. 180 |
| A/C binary switch - high pressure | 23.5 bar (341 lbf/in², 24 kgf/cm²) | p. 180 |
| A/C thermostatic switch - cut out | 32.0°F to 34.0°F (0°C to 1.1°C) | p. 180 |
| A/C thermostatic switch - cut in | 44.0°F to 46.0°F (6.6°C to 7.7°C) | p. 180 |
| 412S | ||
| Pump 1 flow at 2200 engine rev/min | 45.5 l/min (10.0 gal/min) | p. 636 |
| Pump 1 flow at 200 bar (minimum acceptable, worn pump) | 37.0 l/min (8.1 gal/min) | p. 636 |
| Pump 2 flow at 2200 engine rev/min | 65.3 l/min (14.4 gal/min) | p. 636 |
| Pump 2 flow at 200 bar (minimum acceptable, worn pump) | 60.0 l/min (13.2 gal/min) | p. 636 |
| 412S, 414S | ||
| Main relief valve (P1) | 240 bar (245 kgf/cm², 3480 lbf/in²) | p. 636 |
