Page 1

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 Š 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


Section 1 - General Information

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Section 1 - General Information 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

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Section 1 - General Information Contents

1 - ii

Page No.

1 - ii


Section 1 - General Information

Introduction About this Publication This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST!

'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

The manual is compiled in sections, the first three are numbered and contain information as follows:

This Service Manual covers the following machines: 412S Wheeled Loading Shovel from machine serial number 535000 414S Wheeled Loading Shovel from machine serial number 537000 416S Wheeled Loading Shovel from machine serial number 543000

1

General Information - includes torque settings and service tools.

2

Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

The information provided in this manual for the 414S machine also applies to the 416S machine except where speciified.

3

Routine Maintenance - includes service schedules and recommended lubricants for all the machine.

Smoothshift Transmission introduced from the following serial numbers:

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:

412S Wheeled Loading Shovel from machine serial number 535500

A

Attachments

B

Body & Framework...etc.

414S Wheeled Loading Shovel from machine serial number 537300 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 in later issues of the manual.

JCB 444 Series engine added to 412S Wheeled Loading 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.

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Section 1 - General Information

Identifying your Machine Identification Plates Identification Plate Your machine has an identification plate 1X mounted on the left hand side of the machine on the loader arm pillar. The serial numbers of the machine and its major units are stamped on the plate.

identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have.

Unit Identification The engine serial number is stamped on a plate 2Y or 3Y which is fastened to the right side of the cylinder block, near the fuel filter. Note: For machines with the JCB 444 Series engine, see Section K, Technical Data.

Fig 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 = 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)

Fig 2. 412S Machines

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

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Section 1 - General Information Identifying your Machine Identification Plates

Transmission Identification The Transmission serial number is stamped on plate 4Z or 5Z as shown.

Fig 3. 414S Machines

Typical Engine Identification Number

1

1

2

3

4

5

AA

50261

U

500405

P

Engine Type, a

AA = 4 cylinder naturally aspirated

b AB = 4 cylinder turbo 2

Build Number

3

Country of Origin

4

Engine Sequence Number

5

Year of Manufacture

1-3

Fig 4. 412S Machines

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Section 1 - General Information Identifying your Machine Identification Plates

Fig 5. 414S Machines

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Section 1 - General Information

Torque Settings Zinc Plated Fasteners (golden finish) Use only where no torque setting is specified in the text. 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.

Metric Grade 8.8 Bolts Bolt size Dia.

(mm)

UNF Grade `S' Bolts Bolt size Dia.

(mm)

Hexagon

Nm

kgf m

lbf ft

(A/F) mm Torque Settings

Hexagon

Torque Settings

Nm

kgf m

lbf ft

(A/F) mm 1/4

6.3

7/16

14

1.4

10

5/16

7.9

1/2

28

2.8

20

3/8

9.5

9/16

49

5.0

36

7/16

11.1

5/8

78

8.0

58

1/2

12.7

3/4

117

12.0

87

9/16

14.3

13/16

170

17.3

125

5/8

15.9

15/16

238

24.3

175

3/4

19

1 1/8

407

41.5

300

7/8

22.2

1 5/16

650

66.3

480

1

25.4

1 1/2

970

99.0

715

1 1/4

31.7

1 7/8

1940

198.0

1430

1 1/2

38.1

2 1/4

3390

345.0

2500

M5

(5)

8

7

0.7

5

M6

(6)

10

12

1.2

9

M8

(8)

13

28

3.0

21

M10

(10)

17

56

5.7

42

M12

(12)

19

98

10

72

M16

(16)

24

244

25

180

M18

(18)

27

350

36

258

M20

(20)

30

476

48

352

M24

(24)

36

822

84

607

M30

(30)

46

1633

166

1205

M36

(36)

55

2854

291

2105

Rivet Nut Bolts/Screws Bolt size

Torque Settings (for steel rivet nuts)

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.

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Section 1 - General Information 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.

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Section 1 - General Information 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.

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Section 1 - General Information

Service Tools Numerical List Section B - Body and Framework The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail 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)

826/01106

M6 x 19mm Rivet Nut

K Fig 1. ( T 1-9)

826/01177

M8 x 18mm Rivet Nut

K Fig 1. ( T 1-9)

826/01176

M10 x 23mm Rivet Nut

K Fig 1. ( T 1-9)

826/01333

M10 x 26mm 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)

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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework

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 x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, 826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x 26mm Rivet Nut

Note: - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

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

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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework

Fig 5. 926/15500 Note: - used to provide the correct set clearance between glass edge and cab frame. (unit quantity = 500 off)

Fig 7. 992/12800 Note: - used to remove broken glass.

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.

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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework

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.

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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework

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.

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Section 1 - General Information Service Tools Numerical List Section C - Electrics

Numerical List Section C - Electrics The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service .

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail 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)

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Section 1 - General Information 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

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Section 1 - General Information Service Tools Numerical List Section E - Hydraulics

Numerical List Section E - Hydraulics The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service .

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference

1406/0011

Bonded Washer

K Fig 19. ( T 1-18)

1406/0014

Bonded Washer

K Fig 19. ( T 1-18)

1406/0018

Bonded Washer

K Fig 19. ( T 1-18)

1406/0021

Bonded Washer

K Fig 19. ( T 1-18)

1406/0029

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)

816/00190

Blanking Cap

K Fig 22. ( T 1-19)

816/00193

Blanking Cap

K Fig 22. ( T 1-19)

816/00196

Blanking Cap

K Fig 22. ( T 1-19)

816/00197

Blanking Cap

K Fig 22. ( T 1-19)

816/00294

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)

816/55038

Pressure Test Adapter

K Fig 18. ( T 1-18)

816/55040

Pressure Test Adapter

K Fig 18. ( T 1-18)

892/00039

Spool Clamp

K Fig 26. ( T 1-20)

892/00055

Blanking Plug

K Fig 21. ( T 1-19)

892/00056

Blanking Plug

K Fig 21. ( T 1-19)

892/00057

Blanking Plug

K Fig 21. ( T 1-19)

892/00058

Blanking Plug

K Fig 21. ( T 1-19)

892/00059

Blanking Plug

K Fig 21. ( T 1-19)

892/00060

Blanking Plug

K Fig 21. ( T 1-19)

892/00074

Female Connector

K Fig 24. ( T 1-19)

892/00075

Female Connector

K Fig 24. ( T 1-19)

892/00076

Female Connector

K Fig 24. ( T 1-19)

892/00077

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)

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Section 1 - General Information Service Tools Numerical List Section E - Hydraulics Part Number

Description

Tool Detail Reference

892/00253

Pressure Test Kit

K Fig 17. ( T 1-18)

892/00255

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00256

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00257

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00258

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00259

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00260

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00261

Pressure Test Adaptor

K Fig 23. ( T 1-19)

892/00262

Pressure Test Adaptor

K Fig 27. ( T 1-20)

892/00263

Pressure Test Adaptor

K Fig 18. ( T 1-18)

892/00264

Pressure Test Adaptor

K Fig 18. ( T 1-18)

892/00265

Pressure Test Adaptor

K Fig 18. ( T 1-18)

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)

892/00948

Charging Tool

K Fig 28. ( T 1-20)

892/01042

Charging Tool

K Fig 28. ( 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)

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Section 1 - General Information Service Tools Numerical List Section E - Hydraulics The following parts are replacement items for kits and would normally be included in the kit numbers above.

Replacement items for kit no. 892/00253

Part Number

Description

Tool Detail Reference

892/00201

Replacement Gauge

K Fig 17. ( T 1-18)

892/00202

Replacement Gauge

K Fig 17. ( T 1-18)

892/00203

Replacement Gauge

K Fig 17. ( T 1-18)

892/00254

Replacement Hose

K Fig 17. ( T 1-18)

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Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics

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 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point

Fig 19. Bonded Washers 1406/0011 1/4 in BSP

Fig 17. Hydraulic Circuit Pressure test Kit

1406/0018 1/2 in BSP

892/00253 Pressure Test Kit 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/ in2)

1406/0029 1.1/4 in BSP

2

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 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point

1 - 18

1406/0021Bonded Washer

9803/4170-10

1 - 18


Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 1604/0006 Adapter 3/4 in M x 3/4 M BSP 1612/0006 Adapter 3/4 in F x 3/4 M BSP 816/20008 Adapter 3/4 in F x 1/2 M BSP 892/00275 Adapter 1/2 in F x 3/4 M BSP

Fig 23. Pressure Test Adapters 892/00255 1/4 in BSP x Test Point 892/00256 3/8 in BSP x Test Point 892/00257 1/2 in BSP x Test Point 892/00258 5/8 in BSP x Test Point 816/15118 3/4 in BSP x Test Point Fig 21. Female Cone Blanking Cap 892/00055 1/4 in BSP 892/00056 3/8 in BSP

892/00259 1 in BSP x Test Point 892/00260 1.1/4 in BSP x Test Point 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 816/00294 1/4 in BSP 816/00189 3/8 in BSP

892/00075 1/2 in BSP x 1/2 in BSP 892/00076 5/8 in BSP x 5/8 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

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Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics

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)

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Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics

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

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Section 1 - General Information Service Tools Numerical List Section F - Transmission

Numerical List Section F - Transmission The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference

892/00817

Heavy Duty Socket

K Fig 31. ( T 1-23)

892/00818

Heavy Duty Socket

K Fig 31. ( T 1-23)

892/00819

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)

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Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission

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 892/00818 22 mm A/F x 3/4 in. Square Drive 892/00819 15 mm A/F x 1/2 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

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Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission

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

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Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission

Fig 40. 892/01066

Fig 41. 892/01066

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Section 1 - General Information Service Tools Numerical List Section K - Engine

Numerical List Section K - Engine The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference

892/00041

De-glazing Tool

K Fig 42. ( T 1-27)

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Section 1 - General Information 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

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Section 1 - General Information 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 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0651

50 ml

JCB Threadlocker and Sealer

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

400 ml (Aerosol)

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

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Section 2 - Care and Safety

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Section 2 - Care and Safety 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

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Section 2 - Care and Safety Contents

2 - ii

Page No.

2 - ii


Section 2 - Care and Safety

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

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Section 2 - Care and Safety 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.

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Section 2 - Care and Safety 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, earprotectors 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

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Section 2 - Care and Safety Safety Check List Operating Safety

Operating Safety

!MWARNING

!MWARNING

Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it.

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. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus.

!MWARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always 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 use the machine controls as handholds, use the handrails.

INT-3-2-7_1

!MWARNING Engine Panels The engine has exposed rotating parts.

INT-2-1-7_1

!MWARNING Exhaust Gases Breathing the machine exhaust gases can harm and 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 feel drowsy, stop the machine at once and get into fresh air. INT-2-1-10_2

!MWARNING Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

Do not open the bonnet while the engine is running. Keep other people clear while you raise the engine cover using the boom. Do not use the machine with the bonnet open or the cover raised. 5-1-2-1

!MWARNING The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_3

!MWARNING

INT-2-2-6

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

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Section 2 - Care and Safety 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

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Section 2 - Care and Safety Safety Check List Maintenance Safety

Maintenance Safety

!MWARNING

!MDANGER

Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses.

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-3-1-3

INT-3-2-1_3

!MWARNING

!MWARNING

Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.

Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may cause injury. INT-3-1-17

!MWARNING

INT-3-1-5

!MWARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual.

Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8

!MWARNING

5-1-6-1

!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.

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

INT-3-1-8

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MWARNING

Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11_1

INT-3-2-9_1

!MWARNING

!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.

If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

INT-3-1-6

0125

!MWARNING

!MCAUTION

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than 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, diesel fuel or paraffin to clean your skin.

Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-3

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-2-11

!MCAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12

!MWARNING

INT-3-1-4

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

!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-3-2-4

INT-3-1-10_2

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MWARNING

Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:

When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first.

– Damaged hose ends – Chafed outer covers – Balloned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers

INT-3-1-9

– 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 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.

area

with

DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_3

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Section 2 - Care and Safety Safety Check List Safety Decals

Safety Decals Decals on the machine warn you of particular hazards. Each decal is attached close to a part of the machine 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. Keep all decals clean and readable. Replace lost or 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 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

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Section 2 - Care and Safety Safety Check List Safety Decals

Fig 1.

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Section 3 - Routine Maintenance

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Section 3 - Routine Maintenance 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 Automatic Greasing System ................................................................ 3 - 156

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Section 3 - Routine Maintenance Contents Page No. Access Panels ..................................................................................... 3 - 159 Checking the ROPS/FOPS Structure .................................................. 3 - 161 Articulation Lock .................................................................................. 3 - 162 Loader Arm Safety strut ....................................................................... 3 - 163 Electrical System ................................................................................. 3 - 164 Engine ................................................................................................. 3 - 167 Fuel System ......................................................................................... 3 - 174 Hydraulic System ................................................................................. 3 - 178 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 ......................................................................... Health and Safety ................................................................................ Service Schedules ............................................................................... Lubricants and Capacities ................................................................... Cleaning the Machine .......................................................................... Checking for Damage .......................................................................... Seat Belt .............................................................................................. Greasing .............................................................................................. Automatic Greasing System ................................................................ Access Panels ..................................................................................... Checking the ROPS/FOPS Structure .................................................. Articulation Lock .................................................................................. Loader Arm Safety strut ....................................................................... Electrical System ................................................................................. Engine Air Filter ................................................................................... Engine ................................................................................................. Fuel System ......................................................................................... Hydraulic System ................................................................................. Transmission ....................................................................................... Axles .................................................................................................... Tyres and Wheels ................................................................................ Heating and Ventilation ....................................................................... Front Window Washers .......................................................................

3 - ii

3 - 187 3 - 189 3 - 193 3 - 197 3 - 198 3 - 199 3 - 200 3 - 201 3 - 204 3 - 207 3 - 209 3 - 210 3 - 211 3 - 212 3 - 216 3 - 218 3 - 227 3 - 235 3 - 237 3 - 239 3 - 241 3 - 242 3 - 243

3 - ii


Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Pre-Smoothshift Transmission

Routine Maintenance Lubricants and Capacities - Pre-Smoothshift Transmission Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil

ITEM

CAPACITY

Engine Oil

should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.

Table 1. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

412S To Ser. No 535352

-18 to 0° C

10.7 litres (2.4 UK gal)

-10 to 50° C

414S To Ser. No 537160

JCB Torque Converter Fluid API CE, MIL-L2104C/D

16.0 litres (3.5 UK gal)

JCB 15W/40 Multigrade

412S From Ser. No 535353

JCB Super Multigrade 15w/40

10.7 litres (2.4 UK gal)

-10°C to +50°C (14°F to 122°F)

414S From Ser. No 537161

JCB Super Multigrade 10w/30

16.0 litres (3.5 UK gal)

-15°C to +40°C (5°F to 104°F)

412S

(1)

JCB Torque Converter Fluid

414S

(1)

Engine Oil

CF-4/SG, SAE 15w/40 CF-4/SG, SAE 10w/30

Gearbox 18 litres (4.1 UK gal)

API CE, MIL-L2104C/D API CE, MIL-L2104C/D

23 litres (5.1 UK gal)

Axles 412S

24.0 litres (5.3 UK gal)

414S

23.0 litres (5.1 UK gal)

416S Hydraulic System

JCB Special Gear Oil Plus

API GL4(2)

JCB HP32 Hydraulic Fluid

ISO VG32

25.0 litres (5.6 UK gal) (3)

412S

110 litres (24.8 UK gal)

414S

125 litres (27.5 UK gal)

Cooling System

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Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Pre-Smoothshift Transmission ITEM

CAPACITY

412S

26 litres (5.9 UK gal)

414S Fuel System

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

JCB High Performance Antifreeze and Inhibitor ASTM D6210 (see K Coolant Mixtures ( T 3-58))

50 litres (11 UK gal) (4)

412S

125 litres (27.5 UK gal)

Diesel Oil (see K Types of Fuel ( T 3-41))

ASTM D975-66T Nos. 1D, 2D.

414S

140 litres (30.8 UK gal)

Diesel Oil (see K Types of Fuel ( T 3-41))

ASTM D975-66T Nos. 1D, 2D.

JCB HP Grease

Lithium based

Grease Points

(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.

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Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Smoothshift Transmission

Lubricants and Capacities - Smoothshift Transmission Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil

ITEM

CAPACITY

Engine Oil

412S

-10 to 50° C

10.7 litres (2.4 UK gal)

should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below.

Table 2. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

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

412S

24.0 litres (5.3 UK gal)

JCB Special HP Gear Oil

API GL4(2)

414S

23.0 litres (5.1 UK gal)

JCB Special Gear Oil Plus

API GL4(2)

25.0 litres (5.6 UK gal)

JCB Special Gear Oil Plus

API GL4(2)

412S

110 litres (24.2 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

414S

125 litres (27.5 UK gal)

JCB Extreme Performance Multigrade Hydraulic Fluid 46

ISO VG46

416S

125 litres (27.5 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

26 litres (5.7 UK gal)

JCB High Performance Antifreeze and Inhibitor ASTM D6210 (see K Coolant Mixtures ( T 3-58))

Axles

416S (3)

Hydraulic System

Cooling System 412S 414S/416S Fuel System

50 litres (11.0 UK gal)

(4)

412S

125 litres (27.5 UK gal)

414S

140 litres (30.8 UK gal)

Grease Points

Diesel Oil (see K Types of Fuel ( T 3-41))

ASTM D975-66T Nos. 1D, 2D.

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.

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Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Smoothshift Transmission (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)(412S), 110 litre (16.5 UK gal)(414S/416S) 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 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

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Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Tier 2 Engines with Smoothshift

Lubricants and Capacities - Tier 2 Engines with Smoothshift Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are

ITEM

CAPACITY

Engine Oil (Tier 2)

filled at the factory with JCB Extreme Performance 15W/ 40. (See below for full specification.). This oil should be drained after the first 500 hours operation. It is essential that the drained JCB Extreme Performance 15W/40 is replaced only by the lubricant recommended below. (See K Service Schedules ( T 3-12) for Tier 2 requirements.)

Table 3. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

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

412S

24.0 litres (5.3 UK gal)

JCB Special HP Gear Oil

API GL4(2)

414S

23.0 litres (5.1 UK gal)

JCB Special Gear Oil Plus

API GL4(2)

25.0 litres (5.6 UK gal)

JCB Special Gear Oil Plus

API GL4(2)

412S

110 litres (24.2 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

414S

125 litres (27.5 UK gal)

JCB Extreme Performance Multigrade Hydraulic Fluid 46

ISO VG46

416S

125 litres (27.5 UK gal)

JCB HP32 Hydraulic Fluid

ISO VG32

26 litres (5.7 UK gal)

JCB High Performance Antifreeze and Inhibitor ASTM D6210 (see K Coolant Mixtures ( T 3-58))

Axles

416S (3)

Hydraulic System

Cooling System 412S 414S/416S Fuel System

50 litres (11.0 UK gal)

(4)

412S

125 litres (27.5 UK gal)

414S

140 litres (30.8 UK gal)

Grease Points

Diesel Oil (see K Types of Fuel ( T 3-41))

ASTM D975-66T Nos. 1D, 2D.

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.

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Section 3 - Maintenance Routine Maintenance Lubricants and Capacities - Tier 2 Engines with Smoothshift (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)(412S), 110 litre (16.5 UK gal)(414S/416S) 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 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.

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Section 3 - Maintenance 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. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB Extreme Performance 15W/40

ITEM

CAPACITY

Engine Oil. This oil should be drained after the first 500 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB Extreme Performance Engine Oil should also be used whenever a new or reconditioned engine is fitted to the machine. It is essential that the JCB Extreme Performance oil is replaced by the lubricant recommended below.

Table 4. FLUID/LUBRICANT

INTERNATIONAL 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-L2104C/D

Front Axle

23 litres (5.1 UK gal)

JCB LS Gear Oil

API GL4, MIL-L2105A

Rear Axle

23 litres (5.1 UK gal)

JCB LS Gear Oil

API GL4, MIL-L2105A

130 litres (28.6 UK gal)

JCB Hydraulic Fluid

ISO VG46 Multigrade

140 litres (30.1 UK gal)

Diesel Oil (see K Types of Fuel ( T 3-41))

ASTM D975-66T Nos. 1D, 2D.

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))

Hydraulic System(1)

Fuel System(2)

Cooling System

Grease Points

JCB HP Grease

Lithium based

(1) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. (2) An optional additional fuel tank of 110 litres (24.2 UK gal) can be fitted.

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Section 3 - Maintenance 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 engine oil into sewers, drains or on the ground.

Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

Handling New Oil

Hygiene

There are no special precautions needed for the handling 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 the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used oil.

2

Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin: a

Storage

Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

Always keep lubricants out of the reach of children.

c

Never store lubricants in open or unlabelled containers.

Use special hand cleansers to help clean dirty hands.

d Never use petrol, diesel fuel, or paraffin for washing.

Waste Disposal

!MCAUTION

3

Avoid skin contact with oil soaked clothing.

It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.

4

Don't keep oily rags in pockets.

5

Wash dirty clothing before re-use.

6

Throw away oil-soaked shoes.

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with 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.

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Section 3 - Maintenance 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

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Section 3 - Maintenance 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 battery away from sparks and flames.

Symbol

Meaning 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 terminals and burn you.

Shield eyes.

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 minutes before connecting it up.

Explosive Gas.

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 running, otherwise the electrical circuits may be damaged.

GETS ONTO YOUR SKIN Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

INT-3-1-14

5-3-4-3_1

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Section 3 - Maintenance 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

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Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedules A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

!MWARNING Maintenance Maintenance must be done by suitably qualified personnel. Before attempting any maintenance work, make sure the machine is safe. Park on level ground. If it is necessary to work with the loader arms raised, then the loader arm safety strut must be fitted as shown in Loader Arm Safety Strut in MAINTENANCE section. 2-3-1-1

Pre-start Cold Checks, Service Points and Fluid Levels

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. Calendar equivalents: Every 10 Hours

=

Daily

Every 50 Hours

=

Weekly

Every 500 Hours

=

Six Months

Every 1000 Hours

=

Yearly

Every 2000 Hours

=

2 Years

Every 6000 Hours

=

6 Years

Operation

10 Hr(1)

100 Hr(2)

250 Hr

…

… {

…

As and When

500 Hr

1000 2000 Hr Hr

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 Element)

- Change

… …

Fuel Filter

- Drain

…

Fuel Filter

- Change

Coolant Level

- Check

Antifreeze Strength

- Check

Coolant Fuel Sedimenter Fan Belt Tension/Condition

… …

… …

… …

…

… … …

- Drain - Check - Check and Adjust

Valve Clearances (412S AM Build/414S YH Build)(4)

- Check and Adjust

3 - 12

…

… …

- Change

Valve Clearances (412S AB Build/414S YB Build)(4)

Engine Mount Security

…

{ … {

… …

- Check

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{

…

…

…

… …

… {

…

…

…

3 - 12


Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Air Compressor Belt Tension/Condition (if fitted)

Operation

10 Hr(1)

100 Hr(2)

250 Hr

- Check

{

…

- Check

… { { …

As and When

500 Hr

…

1000 2000 Hr Hr

…

…

… …

… …

…

…

…

…

…

… … … …

… … … …

…

…

…

… … …

… …

…

TRANSMISSION AND AXLES Transmission Oil Level Transmission Oil

- Change

Transmission Strainer/Filter

- Change

Axle(s) Oil Level Axle(s) Oil Hub Oil Levels

- Check - Change

Hub Oil

- Change

Prop. Shaft and Universal joints

- Grease

Prop. Shaft Security

…

- Check

{

- Check - Grease

{

Axle Breather(s)

- Clean

Tyre Pressures and Condition

- Check

Wheel Nut Security

- Check

Axle Mount Security

- Check

Transmission Mount Security

- Check

{ … { { {

Centre Prop. Shaft Slide

Parking Brake Operation

…

…

- Check and Adjust

HYDRAULICS Oil Level

- Check

Oil Filter

- Change

Oil

- Sample

Oil

- Change

Suction Strainer Servo Filter Hoses & Pipework - Damage or Leaks Hydraulic Filler Cap

…

… {

…

- Clean

{

- Change - Check

…

… …

… …

… …

… …

… … …

- Change

… … … … …

ELECTRICS Instrument Panel Operation

- Check

Wiring for Chaffing

- Check

Battery Terminals for Condition and Tightness

- Check

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…

{ { {

… … …

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Battery Charge Condition

Operation

10 Hr(1)

100 Hr(2)

- Check

{

- Grease

… … { … … … {

250 Hr

As and When

500 Hr

1000 2000 Hr Hr

BODY AND FRAMEWORK Loader End Pivots 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

Cab Heater Intake Filter

- Clean

… …

Cab Recirculation Filter

- Clean

…

ROPS/FOPS Structures

- Check

Seat Belt Security and Condition

- Check

Windscreen Washer Fluid Level

- Fill

…

(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 Hr(1)

100 Hr(2)

250 Hr

As and When

500 Hr

1000 2000 Hr Hr

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

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{ {

… … …

… … …

… … …

{ { { {

…

…

…

3 - 14


Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

Fuel System For Leaks and Contamination

- Check

Exhaust System Security

- Check

Air Inlet System Security

- Check

Coolant System for Leaks

- Check

10 Hr(1)

100 Hr(2)

250 Hr

{ { { {

As and When

500 Hr

1000 2000 Hr Hr

… …

… …

… …

…

…

…

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

{

MRV Pressure

- Check and Adjust

Steer Circuit MRV Pressure

- Check and Adjust

ARV Pressure

- Check and Adjust

{ { … {

… … …

… …

… …

… …

… …

… …

… … … …

… … … …

… … … …

… … … …

…

…

…

…

… … … …

… … … … … …

HYDRAULICS

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 Parking Brake

- Check - Check and Adjust

{ {

ELECTRICS Starter Motor

- Check

Alternator

- Check

Gauges and Warning Lights

- Check

Proximity Sensor Function

- Check

Cab Switches

- Check

Wiper Motors

- Check

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{ { { { { {

… … … …

3 - 15


Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

Heater

- Check

Other (give details)

- Check

10 Hr(1)

100 Hr(2)

250 Hr

As and When

500 Hr

1000 2000 Hr Hr

… …

CAB Glazing for Correct Fit

- Check

Doors and Hinges

- Check

Tool Kit and Handbook

- Check

Locks and Keys

- Check

Seat/Seat Belts

- Check

…

{ { { { {

PAINTWORK - Check

…

Attachment Circuit Pressures

- Check

{

…

…

…

Operation

- Check

{

…

…

…

… … …

… … …

… … …

Condition ATTACHMENTS

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

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Section 3 - Maintenance 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.

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Section 3 - Maintenance Routine Maintenance Greasing

Fig 1.

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Section 3 - Maintenance 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.

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Section 3 - Maintenance Routine Maintenance Greasing

!MWARNING

Propshafts Total of 7 grease points Note: Centre Propshaft Sliding Spline - grease point 4-1. For interval see K Service Schedules ( T 3-12)

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

Fig 4.

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Section 3 - Maintenance 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 is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped).

You could be killed or injured if the loader control is accidentally operated. Make sure no-one comes near the machine while you remove the safety strut.

13-2-3-7

1

Make sure the parking brake is on, and that the transmission is in neutral.

2

Raise the loader arm to take the weight off the safety strut 5-A. Stop the engine.

3

Remove the strut:

!MWARNING You could be killed or seriously injured if the loader control is accidentally operated. Make sure that noone goes near the machine whilst you fit the safety strut.

2-3-1-3

16-3-1-5

a

1

Empty the bucket and raise the loader arm enough to fit the safety strut 5-A.

b Remove safety strut.

2

Apply the parking brake, put the transmission in neutral and stop the engine.

3

Fit the strut:

c

a

Release securing strap 5-B.

Return the safety strut to its stowage position.

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 the loader arm slowly.

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Fig 5.

3 - 21


Section 3 - Maintenance 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.

2

Apply the parking brake, put the transmission in 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.

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Section 3 - Maintenance Routine Maintenance Articulation Lock

Removing the Articulation Lock

!MWARNING Always make sure the articulation safety lock has been removed before attempting to drive the machine. The machine cannot be steered with the articulation lock fitted.

1

Remove pin 6-A.

2

Return the articulation lock to its stowage position as shown.

3

Lock the articulation lock into its stowage position by replacing pin at position 6-2 as shown.

16-3-1-4

Fig 6.

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Section 3 - Maintenance 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 1

Apply the parking brake, put the transmission in 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 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.

3

If necessary, top up with hydraulic fluid.

4

Open the right side engine cover. Open filler cap 8-B.

5

Top up the system with hydraulic fluid. See 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 8.

!MCAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4

Fig 7.

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Changing the Filter Element

!MWARNING Make the machine safe before working underneath it. 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.

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 9H.

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.

Fig 9.

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Section 3 - Maintenance Routine Maintenance Transmission

Transmission Checking the Oil Level 1

Park the machine on level ground.

2

Apply the parking brake, put the transmission in 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 point 10-A.

Fig 10. 412S (Pre-Smoothshift Transmission)

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)

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Section 3 - Maintenance Routine Maintenance Transmission

Fig 12. 412S (Smoothshift Transmission)

Fig 13. 414S/416S (Smoothshift Transmission)

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Section 3 - Maintenance Routine Maintenance Transmission

Changing the Oil and Filter (412S)

!MWARNING Make the machine safe before working underneath it. 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

!MWARNING When the filter is removed, oil will gush out. Keep to one side when you remove the filter. Fig 14.

4-3-4-3

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. Fig 15.

Note: Do not fill past the top mark on the dipstick.

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Section 3 - Maintenance Routine Maintenance Transmission

Changing the Oil and Filter (414S/416S)

!MWARNING Make the machine safe before working underneath it. 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

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.

6

Fill the system with new oil at dipstick/filler point 16-A.

Note: Do not fill past the top mark on the dipstick.

Fig 17.

Fig 16.

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Section 3 - Maintenance Routine Maintenance Transmission

Changing the Oil and Filter

!MWARNING Make the machine safe before working underneath it. 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

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.

5

Fit the new filter 19-C hand tight only.

6

Fill the system with new oil at dipstick/filler point 18-A.

Fig 19. 412S

Note: Do not fill past the top mark on the dipstick.

Fig 18. 412S

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Section 3 - Maintenance Routine Maintenance Transmission

Fig 20. 414S/416S

Fig 21. 414S/416S

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Section 3 - Maintenance Routine Maintenance Front and Rear Axles

Front and Rear Axles Checking the Oil Level

!MWARNING Make the machine safe before working underneath it. 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

!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.

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Section 3 - Maintenance Routine Maintenance Front and Rear Axles

Changing the Oil

!MWARNING Make the machine safe before working underneath it. 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

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 22B 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 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).

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Fig 24.

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Section 3 - Maintenance Routine Maintenance Engine

Engine Checking the Oil Level

Changing the Oil and Filter

!MCAUTION

!MWARNING

Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

Make the machine safe before working underneath it. 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.

2-3-3-2

Note: The illustration below shows the layout for 412S machines, however, the dipstick and filler points are in similar positions on 414S machines. 1

Park the machine on level ground and lower the attachments to the ground.

2

Stop the engine. Put the transmission in neutral and remove the starter key.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

!MCAUTION 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 the dipstick 25-A.

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

5

If necessary, add the recommended oil through the filler point 25-B. See K Lubricants and Capacities Pre-Smoothshift Transmission ( T 3-1).

1

Do Steps 1 to 3 of Level ( T 3-26).

2 6

Make sure the filler cap and the dipstick are secure. Close and lock the engine cover.

Place a suitable container beneath the drain plug 26A (to catch the oil).

K Checking the Oil

Fig 26. Fig 25.

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Remove drain plug and its 'O' ring and drain the oil from the sump. Renew the 'O' ring.

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Section 3 - Maintenance 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.

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.

Fig 27.

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.

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Section 3 - Maintenance Routine Maintenance Engine

Checking the Oil Level (412S from Serial No. 535650)

Changing the Oil and Filter (412S from Serial No. 535650)

!MCAUTION

!MWARNING

Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

Make the machine safe before working underneath it. 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.

2-3-3-2

Note: The illustration below shows the layout for 412S machines from Serial No. 535650. 1

Park the machine on level ground and lower the attachments to the ground.

2

Stop the engine. Put the transmission in neutral and remove the starter key.

3

Open the right side engine cover.

4

Check that the oil level is between the two marks on the dipstick 28-1.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

!MCAUTION Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2

5

6

If necessary, add the recommended oil through the filler point 28-2. See K Lubricants and Capacities Pre-Smoothshift Transmission ( T 3-1). Make sure the filler cap and the dipstick are secure. Close and lock the engine cover.

Do Steps 1 to 3 of Level ( T 3-26).

2

Place a suitable container beneath the drain plug (to catch the oil).

Note: 412S machines From Serial No. 535650 are fitted 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 time for the oil to pass through the filter element.

9

Smear seal 29-3 on the new filter canister with clean engine oil.

Fig 28.

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K Checking the Oil

1

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Section 3 - Maintenance 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 any spilt oil, refit the filler cap and make sure it is secure. Close the engine cover.

12

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.. 13

Refit the engine shut-off solenoid fuse and start the engine. Check for leaks. When the engine has cooled, check the oil level.

Fig 29.

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Section 3 - Maintenance Routine Maintenance Engine

Checking the Oil Level (414S from Serial No. 537400 & 416S from Serial No. 543250)

!MCAUTION Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2

1

Park the machine on level ground and lower the attachments to the ground.

2

Stop the engine. Put the transmission in neutral and remove the starter key.

3

Open the right side engine cover.

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).

6

Make sure the filler cap and the dipstick are secure. Close and lock the engine cover.

Fig 30.

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Section 3 - Maintenance Routine Maintenance Engine

Changing the Oil and Filter (414S from Serial No. 537400 & 416S from Serial No. 543250)

!MWARNING Make the machine safe before working underneath it. 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

!MCAUTION Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2

1

Park the machine on level ground and lower the attachments to the ground.

2

Stop the engine. Put the transmission in neutral and remove the starter key.

3

Open the left side engine cover.

4

Place a suitable container beneath the drain plug (to catch the oil).

5

Remove the self sealing drain plug outer threaded cover 31-A

10

Add clean engine oil to the new filter canister. Allow time for the oil to pass through the filter element.

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.

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.

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.

14

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 covers.

Fig 31.

6

7

8

9

Clean filter head 33-D. Make sure that the `O' ring is removed.

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Section 3 - Maintenance Routine Maintenance Engine 15

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.). 16

Refit the engine shut-off solenoid fuse and start the engine. Check for leaks. When the engine has cooled, check the oil level.

Fig 32.

Fig 33.

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Section 3 - Maintenance Routine Maintenance Fuel System

Fuel System Types of Fuel

– ASTM D975-91 Class 1-1DA. T3-007_2

Use good quality diesel fuel to get the correct power and performance from your engine.

– JP7, MIL T38219 XF63. – NATO F63.

Sulphur Content

Recommended Fuel Specification

!MCAUTION

– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. – BS2869 Class A2. – ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA. – JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3. Note: Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They have not been tested or approved by the engine manufacturer. They should be added by your fuel supplier who should understand the concentration level necessary. 1

Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.

2

Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.

3

Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).

!MCAUTION

A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. Table 6. Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5

Normal

0.5 to 1.0

0.75 of normal

More than 1.0

0.50 of normal

Aviation Kerosene Fuels Note: Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.

Low Temperature Fuels

Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2

Acceptable Fuel Specification

!MCAUTION The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.

Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter.)

Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl

GEN-9-3

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Section 3 - Maintenance 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

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Filter Note: 414S machines are fitted with dual filters. Repeat the procedure for the second filter. 1

Apply the parking brake, put the transmission in neutral and stop the engine.

2

Open the right side engine cover.

3

Drain off any water in the bowl 34-B by turning tap 34A.

4

Close and lock the engine cover.

!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.

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Section 3 - Maintenance Routine Maintenance Fuel System

Changing the Fuel Filter Element

Cleaning the Sedimenter Bowl

1

Apply the parking brake, put the transmission in neutral and stop the engine.

If bowl 35-B contains sediment carry out the following:-

2

Open the right side engine cover.

3

Hold bowl 34-B and unscrew bolt 34-C, remove bowl and filter element 34-E.

4

Inspect seals 34-D and renew if damaged.

5

Fit new element 34-E, sealing rings 34-D and bowl 34-B. Make sure seals 34-D are seated correctly.

6

Tighten bolt 34-C.

7

Bleed the fuel system. See K Bleeding the System ( T 3-45).

8

Close and lock the engine cover.

1

Hold the bowl 35-B and unscrew nut 35C.

2

Remove the bowl, and wash in clean fuel.

3

Refit the bowl. Make sure the gasket is in good condition and positioned correctly.

4

Re-tighten nut 35-C, taking care not to over-tighten.

5

Bleed the fuel system. See K Bleeding the System ( T 3-45).

Draining the Sedimenter Bowl 1

Apply the parking brake, put the transmission in neutral and stop the engine.

2

Open the left side engine cover.

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 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

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Section 3 - Maintenance Routine Maintenance Fuel System

Bleeding the System

!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

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: 1

Apply the parking brake, put the transmission in neutral and stop the engine.

2

Open the left side engine cover.

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. 5

Close and lock the engine cover.

Fig 36.

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Filter (Spin-on) 1

Apply the parking brake, put the transmission in neutral and stop the engine.

2

Open the right side engine cover.

3

Drain off any water in the bowl 37-A by turning tap 37B.

4

Repeat for second filter.

5

Close and lock the engine cover.

!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

Changing the Fuel Filter Element (Spinon) 1

Apply the parking brake, put the transmission in neutral and stop the engine.

2

Open the right side engine cover.

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.

5

Bleed the fuel system. See K Bleeding the System ( T 3-45).

6

Close and lock the engine cover.

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Fig 37.

3 - 46


Section 3 - Maintenance 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.

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Filter (412S from Serial No. 535650) 1

Apply the parking brake, put the transmission in neutral and stop the engine.

!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.

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

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Section 3 - Maintenance Routine Maintenance Fuel System

Changing the Fuel Filter (412S from Serial No. 535650) 1

Apply the parking brake, put the transmission in neutral and stop the engine.

!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

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

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.

Fig 40.

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. 9

Bleed the fuel system. See K Bleeding the System ( T 3-45).

10

Close the engine canopy.

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Fig 41.

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Sedimenter (412S from Serial No. 535650)

Cleaning the Sedimenter Bowl If bowl 42-B contains sediment carry out the following:-

1

Open the engine canopy and locate sedimenter .

!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

Drain off any water in the bowl by turning tap 42-A.

3

Make sure tap 42-A is turned off and secure.

1

Hold the bowl 42-B and unscrew nut 42-C.

2

Remove the bowl, and wash in clean fuel.

3

Refit the bowl. Make sure the gasket is in good condition and positioned correctly.

4

Re-tighten nut 42-C, taking care not to over-tighten.

5

Bleed the fuel system. See K Bleeding the System ( T 3-45).

!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 42.

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Sedimenter (412S from Serial No. 535705)

Changing the Sedimenter Filter (412S from Serial No. 535705)

1

Note: The fuel sedimenter assembly fitted to the TM300 now incorporates a paper and gauze filter element.

Open the engine canopy and locate sedimenter .

!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.

1

Hold the bolt 43-C and unscrew the bowl 43-B.

2

Remove the bowl

3

Remove the filter element (43-D).

4

Wash out the bowl with clean fuel.

5

Fit a new filter element.

6

Refit the bowl. Make sure the gasket is in good condition and positioned correctly.

0104

2

Drain off any water in the bowl by turning tap 43-A.

3

Make sure tap 43-A is turned off and secure.

!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.

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 tightened. 7

Screw the filter bowl onto the bolt 43-C until the seal contacts the filter head. Tighten the bowl by hand a further 1/4 of a turn.

8

Bleed the fuel system. See K Bleeding the System ( T 3-45).

9

Run the engine and check for leaks.

2-3-3-11

Fig 43.

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Section 3 - Maintenance Routine Maintenance Fuel System

Bleeding the Fuel System (412S from Serial No. 535650)

!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

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. 1

Open the engine canopy.

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.

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Jcb 412s wheeled loader service repair manualsn:535500  
Jcb 412s wheeled loader service repair manualsn:535500  
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