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

This in-depth service manual is designed for professional technicians and engineers working with JCB 411 and 416 Wheeled Loading Shovels. Covering maintenance, diagnostics, systems schematics, and technical procedures, this manual enables precise servicing of driveline, hydraulic, electrical, brake, steering, and engine systems across different model variations and serial ranges.

Model Covers:

This manual provides information for the following model(s) in the JCB machine range:

JCB 411 Wheeled Loading Shovel from serial number 527000, M1241500 onward
JCB 416 Wheeled Loading Shovel from serial number 529000, M1243000 onward

Note: Data and information for 412S Machines in this Service Manual may not be up to date. 412S and 414S Machines are now covered in Service Manual Part Number 9803/4170.

File Format: PDF

Size: 49.78 MB

No. of pages: 863

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Included Sections:

General Information

• VIN and unit identification systems with plate decoding
• Comprehensive torque values for metric and imperial fasteners
• Detailed service tool listings by section with references and diagrams
• Service consumables specification: adhesives, compounds, lubricants

Care and Safety

• Operational safety notices for maintenance and repairs
• Detailed safety procedures, labels, and decal references

Routine Maintenance

• Fluid types, capacities, and change intervals for multiple serial variants
• Daily, periodic, and system-specific checklists for lubrication and servicing
• Inspection protocols for tyres, belts, filters, articulation locks, and structure
• Greasing schedules with component locations (manual and auto systems)
• Maintenance coverage for engines, hydraulics, cooling, brakes, air systems

Body and Framework

• Cab glazing, ROPS/FOPS structure checks, and HVAC service
• Air conditioning fault diagnosis, leak testing, and refrigerant recharge
• Removal/replacement of centre pivot and loader structural components

Electrical Systems

• Wiring schematics by serial number with connector and harness diagrams
• Battery, alternator, and starter motor testing, replacement and overhaul
• Fuse/relay charts, diagnostics, and control systems (ZF, EMS, CAN bus)
• Full layout of trailer, lighting, heater, wiper and auxiliary harnesses

Hydraulic Systems

• System schematics and flow diagrams tailored by model and series
• Loader valve logic: spool types, relief valves, auxiliary services
• Automatic Carry Control (ACCS) operation and diagnostic procedures
• Servo pressure test guides and maintenance procedures for rams and pumps

Transmission

• Powershift gearbox teardown, converter service, clutch repair, stall testing
• Drive axle and final drive diagnostics with crown/pinion setup techniques
• Transmission dump/kickdown wiring and control lever replacement
• WG-110 electronic transmission diagnostics, fault codes, EMS interfacing

Brakes

• 411 servo/power and 416 hydraulic systems: valves, circuits, and pressure settings
• Parking brake types 1 & 2 with adjust procedures and pad renewal
• Brake pedal, accumulator charging, and bleeding protocols

Hydraulic Steering

• Steering unit disassembly and assembly with pressure valve logic
• Hydraulic shock valve and steering circuit description

Engine

• Specifications for Perkins 1004-4TLR, 1004-4THR3, 1104C-44TA, and JCB 444 engines
• Maintenance procedures including belt drive, crankcase ventilation, filters

Note: For further engine details see Engine Manual Publication No. 9806/0100, 9806/2140, and 9806/3000.

This JCB 411 and 416 Service Manual is essential for workshop-level diagnostics and comprehensive mechanical repair in professional fleet operations and equipment service centers.