JCB 411, 416 Wheeled Loading Shovel Service Manual
973 pages · Publication 9803-4150-17
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- Models
- 411, 416 Wheeled
- Serial coverage
- 411 from SN 527000, 416 from SN 529000, 411 from SN 1241500, 416 from SN 1243000, 416 from SN 1317500
- Manual type
- Service Manual
- Pages
- 973
- Publication
- 9803-4150-17
- Condition
- Brand new
What's inside
From the manual's own table of contents: 6 sections, 444 entries. See sample pages (PDF, 442 KB)
General73 topics
- About this Manual
- Machine Model and Serial Number
- Using the Service Manual
- Section Numbering
- Left Side, Right Side
- Cross References
- Identifying Your Machine
- Machine Identification Plate
- Component Identification Plates
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- Numerical List
- Tool Detail Reference
- Section B - Body and Framework
- Section C - Electrics
- Section E - Hydraulics
- Tool Detail Reference Section F - Transmission
- Section H - Steering
- Tool Detail Reference Section K - Engine
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Labels
- Safety Label Identification
- Part Numbers and Descriptions
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Initial Service and Inspection
- Fit for Purpose Tests for Lifting Equipment
- Obtaining Replacement Parts
- Health and Safety
- Lubricants
- Battery
- Service Schedules
- How to Use the Service Schedules
- Calendar Equivalents
- Fluids, Lubricants and Capacities
- Anti-Corrosion Additives
- Coolant Mixtures
- Fuels
- Prepare the Machine for Maintenance
- How to Make the Machine Safe (Loader Arm Lowered)
- How to Make the Machine Safe (Loader Arm Lifted)
- Safety Mechanism
- Cleaning the Machine
- Preparing the Machine for Cleaning
- Checking for Damage
- Check the Machine Body and Structure
- Check the Seat and Seat Belt
- Check the Tyres
- Check the Electrical Circuits
- Check the Hydraulic Hoses and Fittings
- Checking the ROPS/FOPS Structure
- Greasing
- Preparing the Machine for Greasing
- Automatic Greasing System (if fitted)
- Access Panels
- Rear Grille
- Heater Door
- Engine Covers
Section 3 - Routine Maintenance60 topics
- Cleaning the Filter
- Cleaning the Intake Filter
- Cleaning the Recirculation Filters
- Cleaning the Recirculation Filter
- Changing the Elements
- Cleaning the Air Intake Filter
- Cleaning the Re-Circulation Filter (if fitted)
- Brakes
- Park Brake
- Service Brake
- Electrical System
- Battery Isolator Switch (If Fitted)
- Jump Starting The Engine
- Fuses and Relays
- Engine
- Fuel System
- Hydraulic System
- Transmission
- Tyres and Wheels
- Tyre Inflation
- Checking the Wheel Nut Torques
- Windscreen Washers
- Replenishing
- Fire Extinguisher (if fitted)
- Checking the Fire Extinguisher
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hydraulic Hoses
- Disconnecting the Hydraulic Hoses
- Quick Release Couplings
- Air Conditioning Option
- Rivet Nuts
- Fitting Procedure
- Air Conditioning
- R134a Refrigerant
- System Operation
- System Control
- Safety Procedures
- Visual Inspection
- System Diagnosis
- Checking Refrigerant Charge Level
- Leak Testing
- Tightening Leaking Hoses
- Refrigerant Charging and Discharging
- Pressure Switch Assembly
- Condenser
- Adjusting the Compressor Drive Belt
- Early Type
- The Air Conditioning Unit
- The Blower Unit
- Thermostat
- Evaporator
- Later Type
- The Blower Motor
- Glazing
- Direct Glazing
- ROP/FOPS Structure
- Checking
- Removal and Installation
- Removal
- Installation
Section B - Body and Framework27 topics
- Removal and Replacement
- Replacement
- General Electrical Data
- Bulbs
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- Testing
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starter Motor
- Starting Circuit Test
- Wire and Harness Number Identification
- Wire Numbers and Functions
- Wiring Harness Repair
- Repair Procedure
- Introduction to Fault - Finding Techniques
- Harness Routing
- Example of Wire Tracing
Section C - Electrics111 topics
- Fuses, Ignition Switches and Relays
- Instrumentation
- ZF Computer and Gearbox Controller
- Front Wipe, Rear Wipe, Heater/AC and Heated Rear Screen
- Front and Rear Worklights and Beacon
- Roadlights
- Radio, Cigar Lighter, CCTV and Tow Hitch
- Emergency Steer
- 12Volt Trailer Electrics and Loader Functions
- Loader Auxiliaries (Proportional)
- Earthing - Cab and Cab Roof
- Instrumentation EMS (C164)
- Front Wipe, Rear Wipe, Heater/Air Conditioning and Heated Screen
- Steer
- 12V Trailer Electrics and Loader Functions
- Options
- Change Summary
- Primary Fuses, Ignition Switch and Ignition Relays
- Front Wipe, Rear Wipe, Heater/ACU and Heated Rear Screen
- Heated Mirrors, Seat, Reverse Fan and Emergency Steer
- Connector Location and Identification
- Side Console Harness
- Rear Chassis Harness
- Cab Roof Harness
- Front Chassis Harness
- Rear Cab Harness
- Controller Harness
- Rear Grille Harness
- Under Bonnet Light Harness
- Front Chassis Harness A & B - 411 and 416
- Rear Chassis Harness A - 411 and 416
- Rear Chassis Harness B - 411 and 416
- Side Console Harness A - 411 and 416
- Side Console Harness B - 411 and 416
- Front Chassis (HT) Harness
- Side Console Harness (From March `98)
- Cab Roof Harness (From March `98)
- Under Bonnet Harness
- Canopy Harness
- Canopy Fuse Box Harness
- Front Chassis Harness HT
- Engine Harness
- Transmission Harness
- Cab Roof Interior Harness
- Cab Roof Exterior Front Harness
- Cab Roof Exterior Rear Harness
- Cab Harness
- Seat Link Harness
- Throttle Link Harness
- Drawings
- Proportional Auxiliary Harness
- Cab CAN Harness - Small
- CAN Backbone Harness
- Quickhitch Locking Harness
- Multi-Lever Harness
- Trailer Electrics Harness
- Ergotraction Harness
- LiveLink Harness
- System Identification
- General
- HC11 EMS
- HC11 Display Panel
- Description
- Connecting up the Laptop
- Before Starting Service
- On completion of Service
- HC11 EMS - Software
- C164 Display Panel
- EMS Tools
- Flash Loader Program
- Set-up Program
- Diagnostic Program
- Service History Program
- Data Logger Program
- Connecting the Interrogation Lead
- Removal, Inspection and Replacement
- Dismantle and Assemble
- Renewing the Voltage Regulator and Brushes
- Renewing the Drive Pulley
- Renewing the Brush Gear
- Renewing the Starter Solenoid
- Pump
- Relief Valve Operating Pressures
- Loader Valve
- Valve Block Tie-Rods
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Intentionally Blank
- Component Key
- Loader Valve - Arms Raise/Lower
- Loader Valve - Shovel Float
- Loader Valve - Shovel Tip (Regenerative Spool)
- Loader Valve - Shovel Return
- Loader Valve - Load Hold Check Valve
- Auxiliary Services
- Auxiliary Relief Valve Operation
- Pressure relief
- Anti -cavitation
- Main Relief Valve Operation
- Loader Valve - Unloader Operation 1
- Loader Valve - Unloader Operation 2
- Start Up Valve
- Pump Operation
- Pump Pressure/Flow Regulator Valves
- Start Up
- Hydraulic Service Operated
- Minimum Flow/Maximum Pressure
- Loader Valve - Bucket Float
- Loader Valve - Bucket Tip
Section E - Hydraulics108 topics
- Loader Valve - Bucket Return
- Compensator Spool - Operation 1
- Compensator Spool - Operation 2
- Priority Inlet
- Neutral
- Steering
- Full Lock
- Servo Pressures
- Servo Pressure Regulating Valve
- Neutral Standby Pressure
- Service Operating
- Auxiliary Servo Control Valve - Neutral
- Auxiliary Servo Control Valve - Operation
- Main Servo Control Valve - Neutral
- Main Servo Control Valve - Operation
- Main Servo Control Valve
- Flow Metering 1
- Flow Metering 2
- Flow Metering 3
- Flow Metering 4
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Smooth Ride System
- Hydraulic Circuit
- Operation
- Venting the Smooth Ride System
- Accumulators
- Pressure Testing - 416
- Checking Standby Pressure
- Checking Maximum Pressure
- Checking Steering Relief Valve Pressure
- Two - Set Shovel Ram, Head Side
- Checking the Servo Pressure
- Loader ARV - Pressure Testing Using a Hand Pump
- Pressure Testing - 411
- Main Relief Valve - P2 Circuit
- Steer Relief Valve
- Unloader Valve
- Main Relief Valve - P1 Circuiti
- Servo Pressure
- Idle Control Setting
- Hydraulic Pump (Ultra-Type)
- Dismantling
- Inspection
- Assembling
- When Removing
- When Replacing
- Replacing the Pressure/Flow Regulator
- Renewing Drive Shaft Seal
- Dismantling, Inspecting and Assembly
- Dismantling (Husco)
- Assembly
- Dismantling (Rexroth)
- Precautions During Use
- Caution During Use
- Maintenance, Inspection Points
- Typical Ram
- JCB Ram Sealing Procedure
- 4-Spool ZX Valve
- 4-Spool HT Valve
- 3-Spool ZX Valve
- 3-Spool Proportional ZX Valve
- 3-Spool Proportional HT Valve
- 3-Spool HT Valve
- Type 1: Removal and Installation
- Fitting Auxiliary Lever
- Installlation
- Type 2: Removal and Installation
- Hot Test Settings
- Drive Axle - Front and Rear
- Stall Testing
- Preparation
- Preparation for Towing
- Control Valve - Dismantling and Assembly
- Control Valve - Dismantling
- Control Valve - Assembly
- Converter Compartment - Dismantling
- Gearbox - Dismantling
- Clutch K3/K4 - Dismantling
- Clutch K3/K4 - Assembly
- Final Drive - Dismantling
- Final Drive - Assembly
- Gearbox - Assembly
- Converter Compartment - Assembly
- Main Components
- Oil Circulation Schematic
- Power Flow - Forward Speeds
- Power Flow - Reverse Speeds
- Test Points and Connections
- Electro-Hydraulic Shift Control
- Dismantling and Assembly Information
- Hydraulic Control Unit
- Front Axle
- Rear Axle
- Drive Head
- Crown Wheel and Pinion
- Adjustment
- Correct Tooth Marking
- Pinion too Deeply in Mesh
- Pinion too Far Out of Mesh
- Limited Slip Differential Unit
- Dismantling and Assembly
- Differential Oil Seal
- Axle Hub and Driveshaft - Dismantling
Section F - Transmission44 topics
- Axle Hub and Driveshaft - Assembly
- Brakes - Dismantling
- PD 70 (Earlier Axles)
- Brakes - Assembly
- PD 90 and Later PD 70 Axles
- Ergopower Transmission Specification
- Semi-automatic
- Test Procedure (Automatic)
- Fault Finding
- Fault Codes (WG-110)
- Definition of Operating Modes
- Transmission Fault Codes
- Control Lever
- Wiring to Kickdown and Transmission Dump Switches
- Removal and Replacement of Control Lever
- Electronic Monitoring System (EMS) Display Panel
- Servo Brakes
- Power Brakes
- Variflow and 416
- Brake Circuits - Description
- Park Brake (Pre-Smoothshift Transmission)
- Testing the Park Brake
- Park Brake (Smoothshift Transmission)
- Adjusting the Park Brake
- Adjusting the Brake Pads
- Adjusting the Cable Slack
- Renewing the Brake Pads
- Bleeding the System - 411 Variflow and 416
- Type 3
- Park Brake Switch
- Park Brake Lever
- Park Brake Cable
- Park Brake Calliper
- Charging the Accumulators
- Brake Valve - 411 (Servo)
- Setting-Up Procedure
- Checking the Brake Fluid Level - 411 (Servo)
- Bleeding the System
- Brake Valve - 411 (Power Brakes)
- Brake Valve Setting
- System Testing - 411 (Power Brakes)
- Charge Valve - 411 (Power Brakes)
- Brake Pedal - 411 (Power Brakes)
- Bleeding the System - 411 (Power Brakes)
Section G - Brakes15 topics
- Brake Valve - 411 Variflow and 416
- Brake Pressure Setting
- System Testing - 411 Variflow and 416
- Testing the System Pressure (Stored Accumulator Pressure)
- Testing the System Pressure (Brake Pump Test Point)
- Brake Pedal - 411 Variflow and 416
- Information
- Steering Valve - Operation
- Steering Valve - Operation 2 (R. H. turn)
- Steering Valve - Operation 3 (L. H. turn)
- Steering Shock Valve
- Inspecting
- JCB 444 Dieselmax Series
- Unit Identification
- Specifications
Inside this manual
Real pages from this service manual (973 pages). Open the sample pages (PDF, 441 KB)
- Diagram, page 491: Harness and Wire Number Identification
- Specifications, page 611: Section E - Hydraulics
- Troubleshooting, page 866: Section F - Transmission
- Color page, page 368: Section C - Electrics
- Color page, page 584: Section C - Electrics
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 973 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
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Binder not included
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Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).