JCB 412S, 414S, 416S Wheeled Loading Shovel Service Manual (9803/4170-14)

This original JCB factory service manual covers all technical aspects of the JCB 412S, 414S, and 416S Wheeled Loading Shovels. It provides full maintenance instructions, detailed procedures for disassembly and repair, serial-specific specifications, wiring diagrams, and hydraulic schematics for both pre-Smoothshift and Smoothshift transmission variants.

Model Covers:

JCB 412S from Serial Number 535000 (Smoothshift from 535500)
JCB 414S from Serial Number 537000 (Smoothshift from 537300)
JCB 416S from Serial Number 543000 (Smoothshift from 543100)
JCB 444 Series Engine: available for 412S from SN 1242000

Note: The 414S and 416S machines share most technical data except where differences are explicitly noted.

File Format: PDF

Size: 68.65 MB

No. of pages: 1103

Language: English

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

📑 Included Sections:

General Information

• Machine and serial identification
• Standard torque settings and color-coded BSP/hose fittings
• Service tool lists by section (Body, Electrics, Hydraulics, Transmission, Engine)
• Service consumables and sealing compounds

Care and Safety

• General service precautions and safety decals
• Safe maintenance procedures and operator awareness

Routine Maintenance

• Lubricants and fluid capacities by machine and engine version
• Service schedules and greasing points by serial range
• Hydraulic, electrical, cooling, fuel, tyre and inspection routines
• ROPS/FOPS structure and daily checks

Body and Framework

• Cab glazing and ROPS/FOPS frame access
• Cooling pack and air conditioning components
• Centre pivot service procedures and structural checks

Electrical System

• Fuses, relays, battery and alternator testing
• Complete harness layouts by serial number
• Electronic Monitoring System (EMS), HC11, C164 systems
• Circuit diagrams for all serial blocks

Hydraulic System

• Loader valve functions, relief and load-hold valve diagnostics
• Hydraulic schematics, servo control valves and pump settings
• Auxiliary system configuration and ACCS testing

Transmission

• Powershift and Smoothshift transmission teardown and rebuild
• WG110 and WG160 gearbox functional testing
• Clutch K3/K4, converter and final drive assembly
• Front and rear axle service, differential and drive shafts

Braking System

• Service brake and park brake systems (multiple variants)
• Hydraulic circuit description, valves, pedals and accumulator
• Bleeding, testing and system charging

Hydraulic Steering

• Orbitrol steering valve diagnostics and testing
• Disassembly and service of hydraulic steering unit

Engine

• Perkins 1004, 1006 and JCB 444 engine types
• Data by serial number, build variant and Tier level

Note: See Engine Manual Publication Nos. 9806/0100, 9806/2140, 9806/3000 (Tier 2), 9806/3030 (Tier 3).

This JCB 412S, 414S, 416S Service Manual is vital for engineers handling precise diagnostics and component-level repairs on Tier-compliant wheel loaders in demanding environments.