JCB 411, 416 Wheeled Loading Shovel Service Manual – 9803/4150-16

This workshop repair service manual PDF download for the 411, 416 JCB Wheeled Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheeled Loading Shovel 411 – from machine S/N: 527000
JCB Wheeled Loading Shovel 416 – from machine S/N: 529000
JCB Wheeled Loading Shovel 411 – from machine S/N: M1241500
JCB Wheeled Loading Shovel 416 – from machine S/N: M1243000

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/4150-16
Total Pages : 946

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completely searchable PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-4150-16

Section 1 – General Information
General Information
Introduction
About this Publication
Identifying your Machine
Identification Plates
Identification Plate
Explanation of Vehicle Identification Number (VIN)
Unit Identification
Typical Engine Identification Number
Torque Settings
Zinc Plated Fasteners (golden finish)
UNF Grade `S’ Bolts
Metric Grade 8.8 Bolts
Rivet Nut Bolts/Screws
Service Tools
Numerical List Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E – Hydraulics
Tool Detail Reference Section E- Hydraulics
Numerical List Section F – Transmission
Tool Detail Reference Section F – Transmission
Numerical List Section K – Engine
Tool Detail Reference Section K – Engine
Service Consumables
Sealing and Retaining Compounds

Section 2 – Care and Safety
Care and Safety
Safety Check List
Safety Notices
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals

Section 3 – Routine Maintenance
Routine Maintenance (411 before M1241500 and 416 before M1243000)
Lubricants and Capacities
Lubricants and Capacities – North American Capacities and Lubricant Equivalent
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Greasing
Bucket Pivot Points
Loader Arm Pivot Points
Centre Pivot and Steering Ram
Quickhitch Locking Pins
Propshafts
Loader Arm Safety Strut
Installing the Safety Strut
Removing the Safety Strut
Articulation Lock
Installing the Articulation Lock
Removing the Articulation Lock
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Transmission
Checking the Oil Level
Changing the Oil and Filter
Smoothshift Transmission
Changing the Oil and Filter
Front and Rear Axles
Checking the Oil Level
Changing the Oil
Engine
Checking the Oil Level
Changing the Oil and Filter
Checking the Oil Level (416 from Serial No. 530350 and 411 from Serial No. 528050)
Changing the Oil and Filter (416 from Serial No. 530350 and 411 from Serial No. 528050)
Fuel System
Types of Fuel
Filling the Tank
Draining the Fuel Filter
Changing the Fuel Filter Element
Draining the Sedimenter Bowl
Cleaning the Sedimenter Bowl
Bleeding the System
Draining the Fuel Filter
Changing the Fuel Filter Element
Draining the Fuel Filter (416 from Serial No. 530350 and 411 from Serial No. 528050)
Changing the Fuel Filter (416 from Serial No. 530350 and 411 from Serial No. 528050)
Draining the Fuel Sedimenter (416 from Serial No. 530350 and 411 from Serial No. 528050)
Cleaning the Sedimenter Bowl
Bleeding the System (416 from Serial No. 530350 and 411 from Serial No. 528050)
Fuel Pipes (416 from Serial No. 530350 and 411 from Serial No. 528050)
Cooling System
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Checking the Coolant (416 from Serial No. 530350 and 411 from Serial No. 528050)
Coolant Mixtures
Changing the Coolant (416 from Serial No. 530350 and 411 from Serial No. 528050)
Fan Belts
Adjusting the Fan Belt
Air Conditioning Compressor Drive Belt
Brake System
Checking the Brake Fluid Level (411)
Cab Heater Filters
Cleaning the Filter
Cleaning the Intake Filter
Cleaning the Recirculation Filters
Cleaning the Intake Filter
Cleaning the Recirculation Filter
Air Filter
Changing the Elements
Changing the Elements (416 from Serial No. 530350 and 411 from Serial No. 528050)
Routine Maintenance (411 from M1241500, 416 from M1243000)
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Lifting Regulations – Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Lubricants and Capacities
Cleaning the Machine
Inspections
Checking for Damage
Checking the Seat Belt Condition and Security
Greasing
Shovel Pivot Pins
Loader Arm Pivot Points
Centre Pivot
Rear Axle Pivots
Steer Rams
Propshafts
Automatic Greasing System
Grease Points
Filling the Reservoir
Testing the System
Replacing the Fill Point Filter
System Controls
Engine Covers
Opening and Closing the Engine Covers
Rear Grille
Opening the Rear Grille
Closing the Rear Grille
Heater Door
Opening the Heater Door
Closing the Heater Door
Checking the ROPS/FOPS Structure
Articulation Lock
Installing the Articulation Lock
Removing the Articulation Lock
Loader Arm Safety strut
Installing the Safety Strut
Removing the Safety Strut
Electrical System
Battery
Jump Starting The Engine
Fuses and Relays
Engine
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Coolant Mixtures
Draining and Refilling the Coolant
Air Filter
Front End Accessory Drive Belt
Fuel System
Types of Fuel
Filling the Tank
Draining the Water Separator and Fuel Filter
Changing the Water Separator Filter
Cleaning Water Sediment Pump
Changing the Engine Fuel Filter Element
Priming the System
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Transmission
Checking the Oil Level (Engine Running)
Changing the Oil and Filter
Front and Rear Axles
Checking the Differential Oil Level
Draining and Refilling the Differential Oil
Checking the Hub Oil Level
Draining and Refilling the Hub Oil
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Windscreen Washers
Replenishing
Cab Heater Filters
Cleaning the Intake Filter
Routine Maintenance (416 from M1317500)
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Lifting Regulations – Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
How to Use the Service Schedules
Pre-start Cold Checks, Service Points and Fluid Levels
Lubricants and Capacities
Cleaning the Machine
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
Greasing
Shovel Pivot Pins
Loader Arm Pivot Points
Centre Pivot
Steer Rams
Driveshafts
Automatic Greasing System
Grease Points
Filling the Reservoir
Testing the System
Replacing the Fill Point Filter
System Controls
Access Panels
Opening and Closing the Engine Covers
Opening the Rear Grille
Closing the Rear Grille
Opening the Heater Door
Closing the Heater Door
Checking the ROPS/FOPS Structure
Articulation Lock
Installing the Articulation Lock
Removing the Articulation Lock
Loader Arm Safety strut
Installing the Safety Strut
Removing the Safety Strut
Electrical System
Battery
Battery Isolator
Jump Starting the Engine
24 – 12 Volt Power Distribution Board
Engine Air Filter
Cleaning the Air Filter Dust Valve
Changing the Elements
Engine
Checking the Oil Level
Changing the Oil and Filter
Coolant Mixtures
Checking the Coolant Level
Changing the Coolant
Crankcase Ventilation
Front End Accessory Drive Belt
Fuel System
Acceptable and Unacceptable Fuels
Sulphur Content
Effects of Fuel Contaminates
Filling the Tank
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Pre-Filter
Changing the Engine Fuel Filter Element
Bleeding the System
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Transmission
Checking the Oil Level (Engine Running)
Changing the Oil and Filter
Axles
Checking the Differential Oil Level
Draining and Refilling the Differential Oil
Checking the Hub Oil Level
Draining and Refilling the Hub Oil
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Heating and Ventilation
Cleaning the Cab Intake Filter
Front Window Washers
Replenishing

Section B – Body and Framework
Body and Framework
Technical Data
Air Conditioning Option
Cab
Glazing
Direct Glazing
ROP/FOPS Structure
Checking
Cooling Pack
Introduction (416 from Serial No. 530350), (411 from Serial No. 528050)
Removal and Replacement (416 from Serial No. 530350) (411 from Serial No. 528050)
Rivet Nuts
Fitting Procedure
Basic Operation
Air Conditioning
R134a Refrigerant
System Operation
System Control
Safety Procedures
Fault Finding
Air Conditioning
Visual Inspection
System Diagnosis
Service Procedures
Air Conditioning
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Pressure Switch Assembly
Condenser
Adjusting the Compressor Drive Belt
Air Conditioning
Early Type
The Air Conditioning Unit
The Blower Unit
Thermostat
Evaporator
Later Type
The Air Conditioning Unit
The Blower Motor
Thermostat
Evaporator
Centre Pivot
Removal and Replacement
Removal
Replacement

Section C – Electrics
Electrics
Technical Data
General Electrical Data
Bulbs
Fuses and Relays
411 up to Ser. No. 527375, 416 up to Ser No. 529431
Fuses
411 From Ser. No. 527400, 416 From Ser No. 529500
Fuses
Relays
411 From Ser. No. 527850, 416 From Ser No. 530100
Fuses
Primary Fuses
Relays
Diagnostic Connectors
411 From Ser. No. 527957, 416 From Ser No. 530296
Fuses
Primary Fuses
Relays
Diagnostic Connectors
411 From Ser. No. 1241500, 416 From Ser No. 1243000 to 1317499
Secondary Fuses
Relays
Diagnostic Connectors
Primary Fuses
Fuses and Relays, 416 from Serial No. 1317500
Secondary Fuses
Relays
Diagnostic Connectors
Primary Fuses
Primary Fuses (Engine Compartment Forward Bulkhead)
Test Methods
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery, Alternator and Starter Motor
Battery
Maintenance
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Starter Motor
Removal and Replacement
Dismantling
Servicing and Renewal
Assembly
Starter Motor (JCB Engine)
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Brush Gear
Renewing the Starter Solenoid
Alternator (JCB Engine)
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Schematic Circuits
411 from Ser. No. 527000, 416 from Ser. No. 529000
411 up to Ser. No. 527012, 416 up to Ser. No. 529014
Main Components
Lamps
Fuses
411 up to Ser. No. 527399, 416 up to Ser. No. 529499
Main Components
Lamps
Fuses
411 up to Ser. No. 527849, 416 up to Ser. No. 530099
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Main Components
Fuses
Main Components
Lamps
Fuses
411 up to Serial Number 528049, 416 up to Serial Number 530349
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
411 from Ser. No. 527850, 416 from Ser. No. 530100
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
411 from S/N: 528050, 416 from S/N: 530350
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Main Components
Fuses
Main Components
Fuses
Main Components
Fuses
411 from M1241500, 416 from M1243000 to1317499
Primary Fuses, Ignition Switch and Ignition 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
ESOS, Heated Mirrors, Heated and Suspension Seat, Reverse Fan and Emergency Steer
12Volt Trailer Electrics and Loader Functions
Loader Auxiliaries (Proportional)
Earthing – Cab and Cab Roof
416 from Serial No. 1317500
Primary Fuses, Ignition Switch and Ignition Relays
Instrumentation
ZF Computer and Gearbox Controller
Engine ECU (ECM)
Front Wipe, Rear Wipe, Heater/Air Conditioning and Heated Rear Screen
Front and Rear Worklights and Beacon
Roadlights
Radio, Cigar Lighter, CCTV and Tow Hitch
ESOS, Heated Mirrors,Seat, Reverse Fan and Emergency Steer
12 Volt Trailer Electrics and Loader Functions
Loader Auxiliaries (Proportional)
Earthing – Cab and Cab Roof
Fault Finding
Introduction to Fault – Finding Techniques
Harness Routing
Example of Wire Tracing
Harness and Wire Number Identification
Connector Location and Identification
Side Console Harness
Rear Chassis Harness
Cab Roof Harness
Front Chassis Harness
Rear Cab Harness
Front Chassis Harness
Rear Chassis Harness
Side Console Harness
Rear Cab Harness
Cab Roof Harness
Controller Harness
Rear Grille Harness
Under Bonnet Light Harness
Harnesses 411 from Ser. No 527375, 416 from Ser. No. 529431
Front Chassis Harness A & B – 411 & 416
Rear Cab Harness A & B – 411 & 416
Rear Chassis Harness A – 411 & 416
Rear Chassis Harness B – 411 & 416
Side Console Harness A – 411 & 416
Side Console Harness B – 411 & 416
Cab Roof Harness A & B – 411 & 416
Harnesses 411 from Ser. No. 527400, 416 from Ser. No. 529500
Front Chassis (HT) Harness
Rear Chassis Harness
Rear Chassis Harness
Side Console Harness
Side Console Harness
Side Console Harness
Side Console Harness (From March `98)
Side Console Harness (From March `98)
Side Console Harness (From March `98)
Side Console Harness
Side Console Harness
Side Console Harness
Side Console Harness
Rear Cab Harness
Cab Roof Harness
Cab Roof Harness (From March `98)
Controller Harness
Rear Grille Harness
Under Bonnet Harness
Harnesses 411 from Ser. No. 527850, 416 from Ser. No 530100
Canopy Harness
Canopy Harness
Canopy Harness
Canopy Fuse Box Harness
Canopy Fuse Box Harness
Canopy Fuse Box Harness
Front Chassis Harness HT
Rear Chassis Harness
Rear Cab Harness
Cab Roof Harness
Engine Harness
Transmission Harness
Harnesses 411 from M1241500, 416 from M1243000 to 1317499
Cab Roof Interior Harness
Cab Roof Exterior Front Harness
Cab Roof Exterior Rear Harness
Side Console Harness
Transmission Harness
Rear Cab Harness
Front Chassis Harness
Engine Harness
Rear Chassis Harness
Proportional Auxiliary Harness
Rear Grille Harness
CAN Backbone Harness
Quickhitch Locking Harness
Multi-Lever Harness
Drawings
Cab Roof Interior Harness – CAD 721/12156 Issue 2
Cab Roof Exterior Rear Harness – CAD 721/ 12158 – Issue 1
Cab Roof Exterior Front Harness – CAD 721/ 12157 – Issue 1
Side Console Harness – CAD 721/12151 – Issue 1
Transmission Harness – CAD 721/12155 – Issue 1
Rear Cab Harness – CAD 721/12160 Issue 1
Front Chassis Harness – CAD 721/12159 Issue 1
Engine Harness – CAD 721/12153 Issue 1
Rear Chassis Harness – CAD 721/12152 Issue 1
Proportional Auxiliary Harness – CAD 721/ 12247 Issue 1
Rear Grille Harness – CAD 721/12161 Issue 1
CAN Backbone Harness – CAD 727/00011 Issue 1
Quickhitch Locking Harness – CAD 721/11922 Issue 1
Multi-Lever Harness – CAD 721/11967 Issue 1
416 from Serial No. 1317500
Cab Roof Interior Harness
Cab Roof Exterior Front Harness
Cab Roof Exterior Rear Harness
Cab Harness
Rear Cab Harness
Seat Link Harness
Transmission Harness
Front Chassis Harness
Rear Chassis
Engine Harness
Throttle Link Harness
Proportional Auxiliary Harness
Rear Grille Harness
Trailer Electrics
Drawings
Cab Roof Interior Harness – CAD 721/12333 Issue 1
Cab Roof Exterior Front Harness – CAD 721/ 12157 – Issue 2
Cab Roof Exterior Rear Harness – CAD 721/ 12332 – Issue 1
Cab Harness – CAD 721/12385 Issue 3 (5 Sheets)
Rear Cab Harness – CAD 721/12160 Issue 1
Seat Link Harness – CAD 721/12408 – Issue 1
Transmission Harness – CAD 721/12155 – Issue 1
Front Chassis Harness – CAD 721/12159 Issue 3
Rear Chassis Harness – CAD 721/12152 Issue 1
Engine Harness – CAD 721/12504 Issue 1
Throttle Link Harness – CAD 721/12119 – Issue 2
Proportional Auxiliary Harness – CAD 721/ 12247 Issue 1
Rear Grille Harness – CAD 721/12161 Issue 1
Trailer Electrics Harness – CAD 721/12319 Issue 2
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Electric Monitoring System (EMS)
Display Panel
Ignition On
Pre-Start Mode
Setting up
Start Inhibit
Warning Lights
Visual Warning Only
Visual Warning plus Buzzer and Message
Visual Warning and Message
Automatic Engine Shut Down
Segmented Displays
Master Warning Light
Transmission Fault
Indications (Engine Off)
Indications (Engine Running)
Using the Warning Light Test Button (Daily) (To Serial No. 539249)
Warning Light Test (Daily) (From Serial No. 539250)
Description
Introduction
The Main Screen
Flash Downloader
Preparing to Transfer a Program
Transferring the Program
Exiting the Flash Downloader
Settings Editor
Viewing Current Settings
Changing the Settings
Writing Settings to the EMS
Saving Settings to Disk
Loading Settings from Disk
Closing a Settings File
Exiting the Settings Editor
Log Viewer
Downloading Logs from the EMS
Viewing the Logs only
Viewing Logs from a File
Last Minutes Running Data Information
Event Occurrence Information
Service Logs
Printing Logs
Filtering the View
Exiting the Log Viewer
Serial Number Editor
Unlocking the Serial Number
Writing the Serial Number
Refreshing Serial Number Information
Exiting the Serial Number Editor
Connecting up the Laptop
Before Starting Service
On completion of Service
Software
System Operation
Installation
Installation from Techweb
Transfer New Program
Serial Number
Log Data
Fault Limit Settings
Connection of Interrogation Lead

Section E – Hydraulics
Hydraulics
Technical Data
411 Machines
Pump
Relief Valve Operating Pressures
416 Machines
Pump
Loader Valve
Basic System and Operation
General Description
411
416
Circuit Diagrams
411
Component Key
416 To Serial No. 529342
Component Key
416 From Serial No. 529343
Component Key
416 From Serial No. 1243000
Component Key
Descriptions (411)
Loader Valve
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 (ARV) Operation
Pressure relief
Anti -cavitation
Main Relief Valve (MRV) Operation
Loader Valve – Unloader Operation 1
Loader Valve – Unloader Operation 2
Descriptions (416)
Pump Operation
Pump Pressure/Flow Regulator Valves
Start Up
Hydraulic Service Operated
Minimum Flow/Maximum Pressure
Start Up Valve
Loader Valve
Loader Valve – Arms Raise/Lower
Loader Valve – Bucket Float
Loader Valve – Bucket Tip
Loader Valve – Bucket Return
Compensator Spool – Operation 1
Compensator Spool – Operation 2
Auxiliary Services
Priority Inlet
Neutral
Steering
Full Lock
Servo Pressures
Servo Pressure Regulating Valve
Neutral Standby Pressure
Service Operating
Servo Control Valve
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
Pressure Testing
411 Machines
Loader Valve
Main Relief Valve (M.R.V. P2 Circuit)
Steer Relief Valve
Unloader Valve
Main Relief Valve (M.R.V. P1 Circuit)
Servo Pressure
Loader Valve – Pressure Testing
Loader A.R.V. (Using Hand Pump)
Pressure Testing – 416 Machines
Loader Valve
Checking Standby Pressure
Checking Maximum Pressure
Checking Steering Relief Valve Pressure
Two – Set Shovel Ram, Head Side
Checking the Servo Pressure
Pressure Testing the Loader Valve A.R.V.s Using a Hand Pump
Idle Control Setting
Automatic Carry Control System (ACCS)
Introduction
Hydraulic Circuit
Operation
Maintenance Safety
Accumulators
Schematic Circuits
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Pumps
411
Hydraulic Pump (‘Ultra’ type)
Dismantling
Inspection
Assembling
Pumps
416
Removal and Replacement
When Removing
When Replacing
Replacing the Pressure/Flow Regulator
Renewing Drive Shaft Seal
Dismantling, Inspecting and Assembly
Dismantling
Inspecting
Assembly
Loader Valve Block
Removal and Replacement
Removal
Replacement
Dismantling (Husco)
Assembly
Dismantling (Rexroth)
Assembly
Servo Joystick
Removal and Replacement
Removal.
Fitting Auxiliary Lever
Replacement
Rams
Typical Ram
Typical Ram

Section F – Transmission
Transmission
Technical Data
411, 416
411 Drive Axle – Front & Rear
416 Drive Axle – Front & Rear
STALL TESTING
416 Machines Only
WG – 110
Towing Procedure
Preparation
Preparation for Towing
Powershift Transmission
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
WG 110
Main Components
Oil Circulation Schematic
Power Flow – Forward Speeds
Clutches Actuated
Power Flow – Reverse Speeds
Clutches Actuated
Test points and connections
Electro-Hydraulic Shift Control
Dismantling and Assembly Information
Hydraulic Control Unit –
Dismantling
Assembly
Axles
Front Axle
Removal
Replacement
Rear Axle
Removal
Replacement
Drive Head
Dismantling
Assembly
Pinion Depth
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
When Dismantling
When Assembling
Friction Plate Wear Limits
Differential Oil Seal
Removal and Replacement
Axle Hub and Driveshaft – Dismantling
PD 70
Axle Hub and Driveshaft – Assembly
PD 70
Axle Hub and Driveshaft – Dismantling
PD 90
Axle Hub and Driveshaft – Assembly
PD 90
Brakes – Dismantling
PD 70 (Earlier Axles)
Brakes – Assembly
PD 70 (Earlier Axles)
Brakes – Dismantling
PD 90 and Later PD 70 Axles
Brakes – Assembly
PD 90 and Later PD 70 Axles
Functional Testing
Semi – automatic
Test Procedure (Automatic)
Fault Finding
Fault Codes (WG-110)
Introduction
Definition of Operating Modes
NORMAL:
SUBSTITUTE CLUTCH CONTROL:
LIMP-HOME:
TRANSMISSION-SHUTDOWN:
TCU-SHUTDOWN:
Transmission Fault Codes
Replacement
Replacement of Loader Arm Control Transmission Dump and Kickdown Switches
Replacement of Wiring to Kick down and Transmission Dump Switches
Removal and Replacement of Control Lever

Section G – Brakes
Brakes
Technical Data
411 Servo Brakes
411 Power Brakes
411 Variflow and 416
Brake Circuits, Valves and Pedals
Brake Circuits – Description
411 Variflow and 416
Brake Valve – 411 (Servo)
Removal and Replacement
Dismantling and Assembly
Setting-up Procedure
Checking the Brake Fluid Level (411 Servo Brakes Only)
Bleeding the System
Brake Valve – 411 (Power Brakes)
Removal and Replacement
Brake Valve Setting
Dismantling and Assembly
System Testing – 411 (Power Brakes)
Charge Valve – 411 (Power Brakes)
Removal and Replacement
Dismantling and Assembly
Brake Pedal – 411 (Power Brakes)
Removal and Replacement
Bleeding the System – 411 (Power Brakes)
Brake Valve – 411 Variflow and 416
Removal and Replacement
Dismantling and Assembly
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
Removal
Brake System
Bleeding the System – 411 Variflow and 416
Parking Brake
(Type 1)
Adjusting the Parking Brake
Adjusting the Brake Pads
Adjusting the Cable Slack
Renewing the Brake Pads
Dismantling and Assembly
(Type 2)
Adjusting the Parking Brake
Adjusting the Cable Slack
Renewing the Brake Pads
Dismantling
Assembly
Parking Brake (Pre-Smoothshift Transmission)
Testing the Parking Brake
Parking Brake (Smoothshift Transmission)
Testing the Parking Brake
Charging the Accumulators
System Operation

Section H – Hydraulic Steering
Hydraulic Steering
Technical Data
Pump
General Description
Hydraulic Steering Unit
Dismantling
Inspecting
Assembling
Descriptions
Steering Valve – Operation
Steering Valve – Operation 2 (R. H. turn)
Steering Valve – Operation 3 (L. H. turn)
Steering Shock Valve

Section K – Engine
Engine
Technical Data
411
416 from M529000
416 from S/N: No. 530350, 411 from S/N: No. 528050
JCB 444 Series
Unit Identification
Specifications
416 from Serial No. 1317500
Unit Identification
Specifications Tier 3

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