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 JCB 412S, 414S, 416S 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 |
JCB 412S, 414S, 416S Common Problems This Manual Covers
One loader service is slow or will not operate at all
Work through the hydraulics fault finding table. Check the associated ram for leaks and replace its seals if needed. Check the ARV setting and adjust it if it is wrong. If a diverter is not opening, check its electrical power supply and valve operation, then fix what you find.
Manual Section: Hydraulics: Circuit Descriptions, Service and Fault Finding p. 726Every hydraulic ram on the machine is slow to operate
The fault finding table lists the neutral circuit and low pressure lines as a cause when they are leaking, damaged, trapped or kinked. Check each pipe line and replace any that are damaged. The hydraulic schematic circuits and their component keys show you which lines to trace.
Manual Section: Hydraulics: Circuit Descriptions, Service and Fault Finding p. 726The ZF transmission logs a shift lever error code
As the ZF error code tables direct, check the cables running from the TCU to the shift lever. The fault resets by itself once the TCU senses a valid signal for that shift lever position. The same section covers control lever wiring and the ZF operating modes.
Manual Section: Transmission: Diagnostics and Fault Codes p. 967Swapping an attachment with residual pressure trapped in the auxiliary hose line
Before you connect or remove any hydraulic hose, vent the residual hydraulic pressure trapped in the service hose line. The Attachments section covers connecting and disconnecting hydraulic hoses and quick release couplings. Care and Safety also requires you to use only JCB approved attachments specified for your machine.
Manual Section: Attachments p. 172Frequently Asked Questions
A warning came up and the loader says it will shut down. How long do I have?
A 30 second count down to engine shut down starts the moment the warning symbol lights. In an emergency, the MANUAL button resets the counter to 30 seconds, so you can move the machine if necessary. The EMS section lists the shutdown warnings: engine oil pressure low, transmission oil temperature high, brake system pressure low, main steer system, coolant temperature and air filter blocked. p. 606
How do I clear the Service Required message on the display?
On C164 machines, Service Required is reset when your JCB dealer downloads the data. On HC11 machines it resets when a JCB distributor downloads it. The HC11 procedure uses a laptop running JCBTerm: select Get Log Data, then View and Reset, then view the Fault Log. Clicking Reset Logs afterwards clears the EMS memory. p. 606
The dash shows ZFCB ERROR with a number. Where do I find what it means?
When the transmission develops a fault, the EMS shows a fault code to help with diagnosis. The codes are listed in Section F Transmission - Fault Finding. On WG-110/160 boxes, a spanner symbol shows that a fault exists, and the code appears only with the gear selector in neutral. If more than one fault is detected, each code shows for about 1 second. p. 581
All my hydraulics have lost power and the engine tends to stall under load. Where do I start?
The fault finding table points first at insufficient hydraulic fluid, so check for leaks and top up. Other causes it lists include an incorrect pump control setting, low pump flow and a sticking priority valve. An incorrect pump control setting is also the cause given for stalling when the hydraulics are under load. On a 412S, Pump 1 should deliver 45.5 l/min (10.0 gal/min) at 2200 engine rev/min. At 200 bar, 37.0 l/min (8.1 gal/min) is the minimum acceptable for a worn pump. p. 726
What do I need to know before splitting the axle brakes or the limited slip diff?
Before dismantling the limited slip differential, note the relative positions of the friction and counter plates, because they must go back in the same positions. If the plates are worn, renew them as a complete set. On the brakes, soak new plates in JCB Special Gear Oil before assembly, then torque bolts 2 to 400 Nm (295 lbf ft). Those two details alone make the book worth having on an axle job. p. 933
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