JCB 412S WHEELED LOADER Service Repair ManualSN：535500

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electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/4170-14
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
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

1 - 0 1 - 09803/4170-10
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Page No.Contents
1 - i 1 - i
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

Page No.Contents
1 - ii 1 - ii

1 - 1 1 - 19803/4170-10
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.
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.
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!
The manual is compiled in sections, the first three are
numbered and contain information as follows:
1 General Information - includes torque settings and
service tools.
2 Care & Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.
3 Routine Maintenance - includes service schedules
and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
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.
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
All sections are listed on the front cover; tabbed divider
cards align directly with individual sections on the front
cover for rapid reference.
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.
'Left Hand' and 'Right Hand' are as viewed from the rear of
the machine facing forwards.
This Service Manual covers the following machines:
412S Wheeled Loading Shovel from machine serial
number 535000
number 537000
number 543000
The information provided in this manual for the 414S
machine also applies to the 416S machine except where
speciified.
Smoothshift Transmission introduced from the following
serial numbers:
number 535500
number 537300
number 543100
JCB 444 Series engine added to 412S Wheeled Loading
Shovel from machine serial number 1242000.
A Attachments
B Body & Framework...etc.

1 - 2 1 - 29803/4170-10
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.
Fig 1.
Explanation of Vehicle Identification
Number (VIN)
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)
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
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 2. 412S Machines
1 2 3 4 5
SLP 412S0 S E 0527001

1 - 3 1 - 39803/4170-10
Typical Engine Identification Number
1 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
Transmission Identification
The Transmission serial number is stamped on plate 4Z or
5Z as shown.
1 2 3 4 5
AA 50261 U 500405 P

1 - 4 1 - 49803/4170-10

1 - 5 1 - 59803/4170-10
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.
UNF Grade `S' Bolts
Metric Grade 8.8 Bolts
Rivet Nut Bolts/Screws
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Bolt size Torque Settings
Dia. (mm) Hexagon 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
Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
(A/F) mm
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
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

Torque Settings
JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)
1 - 6 1 - 69803/4170-10
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.

Torque Settings
JCB Standard Torque Settings for Hose Ends and Flanged Fittings (Colour Coded)
1 - 7 1 - 79803/4170-10
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.

1 - 8 1 - 89803/4170-10
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)
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)

Service Tools
Tool Detail Reference Section B - Body and Framework
1 - 9 1 - 99803/4170-10
Fig 1.
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
Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
Fig 2. 892/00843
Note: essential for preparing new glass prior to
installation.
Fig 3. 892/00842
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.
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.

Service Tools
1 - 10 1 - 109803/4170-10
Fig 5. 926/15500
Note: - used to provide the correct set clearance
between glass edge and cab frame. (unit quantity = 500
off)
Fig 6. 892/00848
Note: - used to access braided cutting wire (below)
through original polyurethane seal.
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.

Service Tools
1 - 11 1 - 119803/4170-10
Fig 9. 992/12801
Note: - 25 mm (1 in) cut - replacement blades for cut-out
knife (above), (unit quantity = 5 off)
Fig 10. 892/00849
Note: - consumable heavy duty cut-out wire used with
the glass extraction tool (above), (approx 25 m length)
Fig 11. 892/00844
Note: - used to give extended reach for normally
inaccessible areas.
Fig 12. 825/99849
Note: - used with bearing locator to set up Upper Centre
Pivot.
Fig 13. 825/99850
Note: - used with dummy bush to set up Upper Centre
Pivot.

Service Tools
1 - 12 1 - 129803/4170-10
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.

Service Tools
Numerical List Section C - Electrics
1 - 13 1 - 139803/4170-10
Numerical List Section C - Electrics
testing electrics. These tools are available from JCB
Service .
good tool supplier.
Part
Number
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)

Service Tools
Tool Detail Reference Section C - Electrics
1 - 14 1 - 149803/4170-10
Tool Detail Reference Section C - Electrics
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
Fig 16. 993/85700

Service Tools
Numerical List Section E - Hydraulics
1 - 15 1 - 159803/4170-10
testing, removing and replacing hydraulics. These tools
are available from JCB Service .
good tool supplier.
Part
Number
Reference
1406/0011 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)
816/15118 Pressure Test Adapter K Fig 23. ( T 1-19)
816/20008 Adapter K Fig 20. ( T 1-18)
892/00039 Spool Clamp K Fig 26. ( T 1-20)
892/00055 Blanking Plug K Fig 21. ( T 1-19)
892/00074 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)

Service Tools
1 - 16 1 - 169803/4170-10
892/00253 Pressure Test Kit K Fig 17. ( T 1-18)
892/00255 Pressure Test Adaptor K Fig 23. ( T 1-19)
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)
892/01043 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)
Part
Number
Reference

Service Tools
1 - 17 1 - 179803/4170-10
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
Reference
892/00201 Replacement Gauge K Fig 17. ( T 1-18)
892/00254 Replacement Hose K Fig 17. ( T 1-18)

Service Tools
Tool Detail Reference Section E- Hydraulics
1 - 18 1 - 189803/4170-10
Fig 17. Hydraulic Circuit Pressure test Kit
892/00253 Pressure Test Kit
892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2
)
892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2)
892/00203 Replacement gauge 0-400 bar (0-6000 lbf/
in2)
892/00254 Replacement Hose
Fig 18. Pressure Test `T' Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 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
1406/0018 1/2 in BSP
1406/0014 5/8 in BSP
1406/0021 3/4 in BSP
1406/0029 1.1/4 in BSP
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
1406/0021Bonded Washer

Service Tools
1 - 19 1 - 199803/4170-10
1604/0006 Adapter 3/4 in M x 3/4 M BSP
1612/0006 Adapter 3/4 in F x 3/4 M BSP
Fig 21. Female Cone Blanking Cap
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
Fig 22. Male Cone Blanking Cap
816/00294 1/4 in BSP
816/00189 3/8 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
Fig 23. Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
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
Fig 24. Female Connectors
892/00074 3/8 in BSP x 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

Service Tools
1 - 20 1 - 209803/4170-10
Fig 25. Hexagon Spanners for Ram Pistons and End
Caps
992/09300 55 mm
992/09400 65 mm
992/09500 75 mm
992/09600 85 mm
992/09700 95 mm
992/10000 125 mm
Fig 26. Spool Clamps
892/00039 Spool Clamp
992/10100 Spool Clamp
Fig 27. Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in. M BSP x 3/8 in. M BSP Taper
892/00706 Test Probe
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2
)
Fig 28. Accumulator Charge Equipment
892/00239 Charging Tool (Diaphragm Accumulators)
892/01042 Charging Tool (Diaphragm Accumulators)
892/01043 Adatper (use with 892/01042)
892/00948 Charging Tool (Piston Accumulators)

Service Tools
1 - 21 1 - 219803/4170-10
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

Service Tools
Numerical List Section F - Transmission
1 - 22 1 - 229803/4170-10
Numerical List Section F - Transmission
good tool supplier.
Part
Number
Reference
892/00817 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)

Service Tools
Tool Detail Reference Section F - Transmission
1 - 23 1 - 239803/4170-10
Fig 30. 992/07603
Fig 31. Heavy Duty Socket for Durlock Bolts
892/00817 17 mm A/F x 3/4 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.
Fig 33.
892/00865 Computer test harness
892/00866 Computer test indicator box
892/00867 Computer test interrogator box

Service Tools
1 - 24 1 - 249803/4170-10
Fig 34. 892/00859
Fig 35. 892/00862
Fig 36. 892/00864
Fig 37.
1 892/00860 Bearing Remover Shim
2 892/00861 Bearing Remover Base Tool
Fig 38. 892/00863
Fig 39. 892/00891

Service Tools
1 - 25 1 - 259803/4170-10
Fig 40. 892/01066
Fig 41. 892/01066

Service Tools
Numerical List Section K - Engine
1 - 26 1 - 269803/4170-10
Numerical List Section K - Engine
good tool supplier.
Part
Number
Reference
892/00041 De-glazing Tool K Fig 42. ( T 1-27)

Service Tools
Tool Detail Reference Section K - Engine
1 - 27 1 - 279803/4170-10
Tool Detail Reference Section K - Engine
For details of other engine service tools refer to Perkins
Service Manual Publication No. 9806/0100
Fig 42. 892/00041
Note: De-glazing Tool for Cylinder Bores (to assist
bedding-in of new piston rings)

Service Consumables
Sealing and Retaining Compounds
1 - 28 1 - 289803/4170-10
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
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
4102/1212 50 ml
JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important.
4102/0551 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
nuts, bolts, and screws up to 50 mm diameter, and
for hydraulic fittings up to 25 mm diameter.
4101/0550 10 ml
4101/0552 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:
– 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.
993/55700
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

2 - 0 2 - 09803/4170-10

Page No.Contents
2 - i 2 - i
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

Page No.Contents
2 - ii 2 - ii

2 - 1 2 - 19803/4170-10
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

Safety Check List
Safety - Yours and Others
2 - 2 2 - 29803/4170-10
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.

Safety Check List
General Safety
2 - 3 2 - 39803/4170-10
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, ear-
protectors 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

Safety Check List
Operating Safety
2 - 4 2 - 49803/4170-10
Operating Safety
!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.
INT-2-1-3
!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-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.
INT-2-2-6
!MWARNING
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.
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 self-
contained breathing apparatus.
INT-3-2-7_1
!MWARNING
Engine Panels
The engine has exposed rotating parts.
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
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

Safety Check List
Operating Safety
2 - 5 2 - 59803/4170-10
!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

Safety Check List
Maintenance Safety
2 - 6 2 - 69803/4170-10
Maintenance Safety
!MWARNING
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.
INT-3-1-3
!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.
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.
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.
INT-3-1-8
!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
!MWARNING
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
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
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

Safety Check List
Maintenance Safety
2 - 7 2 - 79803/4170-10
!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.
INT-3-2-9_1
!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
!MWARNING
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.
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-3-1-4
!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
!MWARNING
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
!MWARNING
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.
0125
!MCAUTION
Cleaning
Cleaning metal parts with incorrect solvents can
cause corrosion. Use only recommended cleaning
agents and solvents.
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
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
INT-3-2-4

Safety Check List
Maintenance Safety
2 - 8 2 - 89803/4170-10
!MWARNING
Battery Terminals
The machine is negatively earthed. Always connect
the negative pole of the battery to earth.
When connecting the battery, connect the earth (-)
lead last.
When disconnecting the battery, disconnect the earth
(-) lead first.
INT-3-1-9
!MWARNING
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 area with
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.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
INT-3-3-5_3
!MWARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
– Damaged hose ends
– Chafed outer covers
– Balloned outer covers
– Kinked or crushed hoses
– Embedded armouring in outer covers
– Displaced end fittings.
INT-3-3-2

Safety Check List
Safety Decals
2 - 9 2 - 99803/4170-10
Safety Decals
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.
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
You can be injured if you do not obey the decal safety
instructions.
where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.
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

Safety Check List
Safety Decals
2 - 10 2 - 109803/4170-10
Fig 1.

3 - 0 3 - 09803/4170-12

Page No.Contents
3 - i 3 - i
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

Page No.Contents
3 - ii 3 - ii
Access Panels ..................................................................................... 3 - 159
Engine ................................................................................................. 3 - 167
Fuel System ......................................................................................... 3 - 174
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 ......................................................................... 3 - 187
Health and Safety ................................................................................ 3 - 189
Service Schedules ............................................................................... 3 - 193
Lubricants and Capacities ................................................................... 3 - 197
Cleaning the Machine .......................................................................... 3 - 198
Checking for Damage .......................................................................... 3 - 199
Seat Belt .............................................................................................. 3 - 200
Greasing .............................................................................................. 3 - 201
Access Panels ..................................................................................... 3 - 207
Engine Air Filter ................................................................................... 3 - 216
Engine ................................................................................................. 3 - 218
Fuel System ......................................................................................... 3 - 227
Transmission ....................................................................................... 3 - 237
Axles .................................................................................................... 3 - 239
Tyres and Wheels ................................................................................ 3 - 241
Heating and Ventilation ....................................................................... 3 - 242
Front Window Washers ....................................................................... 3 - 243

Section 3 - Maintenance
Routine Maintenance
Lubricants and Capacities - Pre-Smoothshift Transmission
3 - 1 3 - 19803/4170-12
Routine Maintenance
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
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.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil 412S To Ser. No
535352
-18 to 0° C 10.7 litres (2.4 UK gal) JCB Torque Converter Fluid
-10 to 50° C 414S To Ser. No
537160
API CE, MIL-L-
2104C/D
16.0 litres (3.5 UK gal) JCB 15W/40 Multigrade
Engine Oil 412S From Ser. No
535353
JCB Super Multigrade 15w/40 CF-4/SG, SAE
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 CF-4/SG, SAE
10w/30
16.0 litres (3.5 UK gal) -15°C to +40°C (5°F to 104°F)
Gearbox
412S (1)18 litres (4.1 UK gal) JCB Torque Converter Fluid API CE, MIL-L-
2104C/D
414S (1)
23 litres (5.1 UK gal) API CE, MIL-L-
2104C/D
Axles
412S 24.0 litres (5.3 UK gal) JCB Special Gear Oil Plus API GL4(2)
414S 23.0 litres (5.1 UK gal)
416S 25.0 litres (5.6 UK gal)
Hydraulic System(3)
412S 110 litres (24.8 UK gal) JCB HP32 Hydraulic Fluid ISO VG32
414S 125 litres (27.5 UK gal)
Cooling System

Routine Maintenance
3 - 2 3 - 29803/4170-12
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.
412S 26 litres (5.9 UK gal) JCB High Performance Antifreeze and Inhibitor
(see K Coolant Mixtures ( T 3-58))
ASTM D6210
414S 50 litres (11 UK gal)
Fuel System(4)
412S 125 litres (27.5 UK gal) Diesel Oil (see K Types of Fuel ( T 3-41)) ASTM D975-66T
Nos. 1D, 2D.
Nos. 1D, 2D.
Grease Points 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.
(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
SPECIFICATION

Routine Maintenance
Lubricants and Capacities - Smoothshift Transmission
3 - 3 3 - 39803/4170-12
filled at the factory with JCB 10W/30 Multigrade oil. This 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
machine. After the first 100 hours operation, it is essential
that the 10W/30 oil is replaced by the lubricant
recommended below.
Table 2.
SPECIFICATION
Engine Oil 412S
-10 to 50° C 10.7 litres (2.4 UK gal) 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
Axles
412S 24.0 litres (5.3 UK gal) JCB Special HP Gear Oil API GL4(2)
Hydraulic System(3)
414S 125 litres (27.5 UK gal) JCB Extreme Performance Multigrade
Hydraulic Fluid 46
ISO VG46
Cooling System
ASTM D6210
414S/416S 50 litres (11.0 UK gal)
Fuel System(4)
Nos. 1D, 2D.

Routine Maintenance
3 - 4 3 - 49803/4170-12
intervals.
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
(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.

Routine Maintenance
Lubricants and Capacities - Tier 2 Engines with Smoothshift
3 - 5 3 - 59803/4170-12
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.
SPECIFICATION
Engine Oil (Tier 2) 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
Axles
412S 24.0 litres (5.3 UK gal) JCB Special HP Gear Oil API GL4(2)
Hydraulic System(3)
414S 125 litres (27.5 UK gal) JCB Extreme Performance Multigrade
Hydraulic Fluid 46
ISO VG46
Cooling System
ASTM D6210
414S/416S 50 litres (11.0 UK gal)
Fuel System(4)
Nos. 1D, 2D.

Routine Maintenance
3 - 6 3 - 69803/4170-12
intervals.
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.
(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.

Routine Maintenance
Lubricants and Capacities - 414S From 537400 & 416S From 543250
3 - 7 3 - 79803/4170-12
Lubricants and Capacities - 414S From 537400 & 416S From 543250
filled at the factory with JCB Extreme Performance 15W/40
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
machine. It is essential that the JCB Extreme Performance
oil is replaced by the lubricant recommended below.
Table 4.
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-L-
2104C/D
Front Axle 23 litres (5.1 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Rear Axle 23 litres (5.1 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Hydraulic System(1)
130 litres (28.6 UK gal) JCB Hydraulic Fluid ISO VG46
Multigrade
Fuel System(2)
(2) An optional additional fuel tank of 110 litres (24.2 UK gal) can be fitted.
140 litres (30.1 UK gal) Diesel Oil (see K Types of Fuel ( T 3-41)) ASTM D975-66T
Nos. 1D, 2D.
Cooling System
35 litres (7.7 UK gal) JCB High Performance Antifreeze and Inhibitor
(see K Coolant Mixtures (414S from Serial
No. 537400 & 416S from Serial No.
543250) ( T 3-67))
ASTM D6210

Routine Maintenance
Health and Safety
3 - 8 3 - 89803/4170-12
Health and Safety
T3-001_3
Lubricants
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.
Hygiene
JCB lubricants are not a health risk when used properly for
their intended purposes.
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.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
!MCAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
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.
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.
Handling
New Oil
There are no special precautions needed for the handling
or use of new oil, beside the normal care and hygiene
practices.
Used Oil
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 Wash your skin thoroughly with soap and water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel, or paraffin for
washing.
3 Avoid skin contact with oil soaked clothing.
4 Don't keep oily rags in pockets.
5 Wash dirty clothing before re-use.
6 Throw away oil-soaked shoes.

Routine Maintenance
Health and Safety
3 - 9 3 - 99803/4170-12
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

Routine Maintenance
Health and Safety
3 - 10 3 - 109803/4170-12
Battery
!MWARNING
Batteries give off an explosive gas. Do not smoke
when handling or working on the battery. Keep the
battery away from sparks and flames.
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.
Set all switches in the cab to OFF before
disconnecting and connecting the battery. When
disconnecting the battery, take off the earth (-) lead
first.
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.
When reconnecting, fit the positive (+) lead first.
First Aid - Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
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.
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns
with a sterile dressing then get medical help.
5-3-4-3_1
Warning Symbols
The following warning symbols may be found on the
battery.
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
Symbol Meaning
Keep away from children.
Shield eyes.
No smoking, no naked flames, no sparks.
Explosive Gas.
Battery acid.
Note operating instructions.

Routine Maintenance
Health and Safety
3 - 11 3 - 119803/4170-12
!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

Routine Maintenance
Service Schedules
3 - 12 3 - 129803/4170-12
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
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
Pre-start Cold Checks, Service Points and
Fluid Levels
Operation 10
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
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 - Change
Fuel Sedimenter - Drain
Fan Belt Tension/Condition - Check
Valve Clearances (412S AB Build/414S YB
Build)(4)
- Check and Adjust
Valve Clearances (412S AM Build/414S YH
Build)(4)
- Check and Adjust
Engine Mount Security - Check

Routine Maintenance
Service Schedules
3 - 13 3 - 139803/4170-12
Air Compressor Belt Tension/Condition (if fitted) - Check
TRANSMISSION AND AXLES
Transmission Oil Level - Check
Transmission Oil - Change
Transmission Strainer/Filter - Change
Axle(s) Oil Level - Check
Axle(s) Oil - Change
Hub Oil Levels - Check
Hub Oil - Change
Prop. Shaft and Universal joints - Grease
Prop. Shaft Security - Check
Centre Prop. Shaft Slide - Grease
Axle Breather(s) - Clean
Tyre Pressures and Condition - Check
Wheel Nut Security - Check
Axle Mount Security - Check
Transmission Mount Security - Check
Parking Brake Operation - Check and Adjust
HYDRAULICS
Oil Level - Check
Oil Filter - Change
Oil - Sample
Oil - Change
Suction Strainer - Clean
Servo Filter - Change
Hoses & Pipework - Damage or Leaks - Check
Hydraulic Filler Cap - Change
ELECTRICS
Instrument Panel Operation - Check
Wiring for Chaffing - Check
Battery Terminals for Condition and Tightness - Check
Fluid Levels
Operation 10
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
Hr

Routine Maintenance
Service Schedules
3 - 14 3 - 149803/4170-12
Battery Charge Condition - Check
BODY AND FRAMEWORK
Loader End Pivots - Grease
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
Windscreen Washer Fluid Level - Fill
Cab Heater Intake Filter - Clean
Cab Recirculation Filter - Clean
ROPS/FOPS Structures - Check
Seat Belt Security and Condition - Check
(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.
Fluid Levels
Operation 10
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
Hr
Functional Test and and Final Inspection Operation 10
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
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

Routine Maintenance
Service Schedules
3 - 15 3 - 159803/4170-12
Fuel System For Leaks and Contamination - Check
Exhaust System Security - Check
Air Inlet System Security - Check
Coolant System for Leaks - Check
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
HYDRAULICS
MRV Pressure - Check and Adjust
Steer Circuit MRV Pressure - Check and Adjust
ARV Pressure - Check and Adjust
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 - Check
Parking Brake - Check and Adjust
ELECTRICS
Starter Motor - Check
Alternator - Check
Gauges and Warning Lights - Check
Proximity Sensor Function - Check
Cab Switches - Check
Wiper Motors - Check
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
Hr

Routine Maintenance
Service Schedules
3 - 16 3 - 169803/4170-12
Table 5. Key
Heater - Check
Other (give details) - Check
CAB
Glazing for Correct Fit - Check
Doors and Hinges - Check
Tool Kit and Handbook - Check
Locks and Keys - Check
Seat/Seat Belts - Check
PAINTWORK
Condition - Check
ATTACHMENTS
Attachment Circuit Pressures - Check
Operation - Check
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.
Hr(1)
100
Hr(2)
250
Hr
As
and
When
500
Hr
1000
Hr
2000
Hr
Regular Maintenance Check
Initial 100 Hour Check Only

Routine Maintenance
Greasing
3 - 17 3 - 179803/4170-12
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.

Routine Maintenance
Greasing
3 - 18 3 - 189803/4170-12
Fig 1.

Routine Maintenance
Greasing
3 - 19 3 - 199803/4170-12
Centre Pivot and Steering Ram
Total of 7 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 2.
Quickhitch Locking Pins
Attachments must be removed in order to grease the
locking pins.
Fig 3.
Note: When working in arduous conditions, grease and
operate the locking pins every 10 hours.

Routine Maintenance
Greasing
3 - 20 3 - 209803/4170-12
Propshafts
Note: Centre Propshaft Sliding Spline - grease point 4-1.
!MWARNING
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.

Routine Maintenance
Loader Arm Safety Strut
3 - 21 3 - 219803/4170-12
Loader Arm Safety Strut
Installing the Loader Arm Safety Strut
!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).
13-2-3-7
!MWARNING
You could be killed or seriously injured if the loader
control is accidentally operated. Make sure that no-
one goes near the machine whilst you fit the safety
strut.
16-3-1-5
1 Empty the bucket and raise the loader arm enough to
fit the safety strut 5-A.
2 Apply the parking brake, put the transmission in
neutral and stop the engine.
3 Fit the strut:
a 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.
Removing the Loader Arm Safety Strut
!MWARNING
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.
2-3-1-3
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:
a Release securing strap 5-B.
b Remove safety strut.
c Return the safety strut to its stowage position.
Fig 5.

Routine Maintenance
Articulation Lock
3 - 22 3 - 229803/4170-12
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.
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.

Routine Maintenance
Articulation Lock
3 - 23 3 - 239803/4170-12
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.
16-3-1-4
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.
Fig 6.

Routine Maintenance
Hydraulic System
3 - 24 3 - 249803/4170-12
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
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 7.
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

Routine Maintenance
Hydraulic System
3 - 25 3 - 259803/4170-12
Changing the Filter Element
!MWARNING
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 9-
H.
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.

Routine Maintenance
Transmission
3 - 26 3 - 269803/4170-12
Transmission
Checking the Oil Level
1 Park the machine on level ground.
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.
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 10. 412S (Pre-Smoothshift Transmission)
Fig 11. 414S/416S (Pre-Smoothshift Transmission)

Routine Maintenance
Transmission
3 - 27 3 - 279803/4170-12
Fig 12. 412S (Smoothshift Transmission)
Fig 13. 414S/416S (Smoothshift Transmission)

Routine Maintenance
Transmission
3 - 28 3 - 289803/4170-12
Changing the Oil and Filter (412S)
!MWARNING
GEN-4-1_1
!MWARNING
When the filter is removed, oil will gush out. Keep to
one side when you remove the filter.
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.
Note: Do not fill past the top mark on the dipstick.
Fig 14.
Fig 15.

Routine Maintenance
Transmission
3 - 29 3 - 299803/4170-12
Changing the Oil and Filter (414S/416S)
!MWARNING
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.
Fig 16.
Fig 17.

Routine Maintenance
Transmission
3 - 30 3 - 309803/4170-12
Changing the Oil and Filter
!MWARNING
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.
Fig 18. 412S
Fig 19. 412S

Routine Maintenance
Transmission
3 - 31 3 - 319803/4170-12
Fig 20. 414S/416S
Fig 21. 414S/416S

Routine Maintenance
Front and Rear Axles
3 - 32 3 - 329803/4170-12
!MWARNING
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.

Routine Maintenance
3 - 33 3 - 339803/4170-12
Changing the Oil
!MWARNING
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
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 22-
B 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).
Fig 23.
Fig 24.

Routine Maintenance
Engine
3 - 34 3 - 349803/4170-12
Engine
!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
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.
4 Check that the oil level is between the two marks on
the dipstick 25-A.
5 If necessary, add the recommended oil through the
filler point 25-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 25.
Changing the Oil and Filter
!MWARNING
GEN-4-1_1
!MCAUTION
2-3-3-2
Note: 414S machines are fitted with dual filter canisters.
Repeat the procedure for the second filter.
1 Do Steps 1 to 3 of K Checking the Oil
Level ( T 3-26).
2 Place a suitable container beneath the drain plug 26-
A (to catch the oil).
Fig 26.
3 Remove drain plug and its 'O' ring and drain the oil
from the sump. Renew the 'O' ring.

Routine Maintenance
Engine
3 - 35 3 - 359803/4170-12
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.
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.
Fig 27.

Routine Maintenance
Engine
3 - 36 3 - 369803/4170-12
Checking the Oil Level (412S from Serial
No. 535650)
!MCAUTION
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.
4 Check that the oil level is between the two marks on
the dipstick 28-1.
5 If necessary, add the recommended oil through the
filler point 28-2. 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 28.
Changing the Oil and Filter (412S from
Serial No. 535650)
!MWARNING
GEN-4-1_1
!MCAUTION
2-3-3-2
1 Do Steps 1 to 3 of K Checking the Oil
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.

Routine Maintenance
Engine
3 - 37 3 - 379803/4170-12
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.

JCB 412S WHEELED LOADER Service Repair ManualSN：535500

JCB 412S WHEELED LOADER Service Repair ManualSN：535500

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JCB 412S WHEELED LOADER Service Repair ManualSN：535500