Month: August 2018

Complete workshop & service manual with electrical wiring diagrams for JCB 427, 437, 457 Wheeled Loading Shovel. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB 427, 437, 457 Wheeled Loading Shovel service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9813-1600 – JCB 427, 437, 457 Wheeled Loading Shovel Service Manual.pdf

EXCERPT:
Service Manual
Wheeled Loading Shovel – 427, 437 and 457
Section 1 – General Information
Section 2 – Care and Safety
Section 3A – Routine Maintenance
Section 3B – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine
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Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– 427 T4i from 2063050
– 437 T4i from 2063202
– 457 T4i from 1907000.
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Hydraulic Control Unit
Dismantling
K Fig 441. ( T F-149).
1 Match-mark relative to each other the relevant positions of valve housing 1, housing covers 12 and 15, and end covers 2 and 3.
2 Remove socket head screws 5.
Separate duct plate 6, gasket 7, intermediate plate 8 and gasket 9 from the valve housing.
3 Remove retaining clip 10.
4 Remove socket head screws 11 and 14.
Separate cover 2 and gasket 2A from housing 12 and cable harness 4. Separate cover 3 and gasket 3A from housing 15.
5 Disconnect cable harness 4 from the pressure regulators 17 (3 off) and 29 (3 off) and remove.
6 Remove the three socket head screws 18, fixing plates 19 and pressure regulators 17.
7 Remove the two outermost socket head screws 20 and replace provisionally with adjusting screws.
Remove the remaining socket head screws 20.
8 Separate housing 12 and gasket 13 from valve housing 1 by loosening the compression tools uniformly to release the spring loading.
9 Remove components 21/22 (1 off), 23/24 (3 off) and -25/ 26 (3 off).
10 Remove the three socket head screws 27, fixing plates 28 and pressure regulators 29.
11 Remove the two outermost socket head screws 30 and replace provisionally with adjusting screws (M5).
Remove the remaining socket head screws 30.
12 Separate housing 15 and gasket 16 from valve housing 1 by loosening the adjusting screws uniformly to release the spring loading.
13 Remove components 441-31/32 (1 off), 441-33/34 (3 off) and 441-35/ 36 (3 off).
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Pages from 9803-4160-17 – JCB 426, 435, 436, 446 Wheeled Loading Shovel Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB 426, 435, 436, 446 Wheeled Loading Shovel. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB 426, 435, 436, 446 Wheeled Loading Shovel service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-4160-15 – JCB 426, 436, 446 Wheeled Loading Shovel Service Manual.pdf
9803-4160-17 – JCB 426, 435, 436, 446 Wheeled Loading Shovel Service Manual.pdf

EXCERPT:
Service Manual
Wheeled Loading Shovel – 426, 435, 436, 446
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Hydraulic Steering
Section K – Engine
…
Assembly
Wash all components in a suitable aromatic solvent. When dry apply hydraulic fluid immediately to prevent moisture collecting.
1 Install a new shaft seal 2 into the mounting flange 3, with the part number of the seal facing outwards.
Press the new seal into its bore until fully seated.
Install the circlip 1 into its groove in the mounting flange 3.
2 Place the front 6 and rear 13 bearing blocks on a clean work bench with the E-seal grooves facing upwards. Apply a coating of petroleum jelly to the grooves. Apply a coating of petroleum jelly to the Eseals and back-up seals. (This will help keep the seals in place during assembly.)
3 Place the E-seals 5 and 14, flat side outwards, into the bearing blocks 6 and 13. Carefully place the backup seals 4 and 15, with the flat side outwards, in the respective groove made by the E-seal and the groove in the bearing block.
Note: In the centre of the back-up seal and the E-seal there is a “notch”. Make sure these notches line up, so that the back-up seal sits flush with the E-seal.
4 Place the mounting flange 3, with the seal side facing downwards on a clean flat surface.
5 Apply a light coating of petroleum jelly to the exposed face of the front bearing block 6.
6 Insert the drive end of the driveshaft 12 through the bearing block 6 with the seal side down, and the open side of the E-seal pointing to the intake side of the motor.
7 Install a sleeve over the driveshaft threads to protect the seal 2 and carefully slide the driveshaft through the seal 2. Remove the sleeve from the driveshaft.
8 Install the idler gear shaft 11 into the remaining position in the bearing block. Apply a light coat of clean hydraulic oil to the face of the driveshaft and idler gears.
9 Pick up the rear bearing block 13, with the seals facing upwards and the open ends of the E-seals facing the intake side of the motor, and place over the driveshaft and idler gear shafts.
10 Ensure the dowel pins 8 are in place in the housing 9.
Note: On later housings there are two long dowels through the housing that locate in the front mounting flange and the rear cover. These replace the four short dowels item 8.
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Pages from 9803-4170 – JCB Wheeled Loading Shovel 412S, 414S, 416S Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Wheeled Loading Shovel 412S, 414S, 416S. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Wheeled Loading Shovel 412S, 414S, 416S service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

9803-4170 – JCB Wheeled Loading Shovel 412S, 414S, 416S Service Manual.pdf

EXCERPT:
Service Manual
Wheeled Loading Shovel – 412S, 414S, 416S
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Hydraulic Steering
Section K – Engine
…
Basic System and Operation
General Description
The main components of the 412S and 414S Wheeled Loader hydraulic systems are the pumps, loader valve block, priority valve, servo-valve, steering valve, brake valve, tank, rams and filters. For descriptions of the steering and brake valves, refer to the relevant sections.
The pumps (PI and P2) are installed as a single unit and driven by the engine to supply pressurised oil to the system. P1 supplies the system and the loader block spools to give the lift and bucket services. P2 supplies the loader block auxiliary (if installed) and Quickhitch service spools only. The output from P2 can be sent to the tank by the operation of the loader block unloading spool and this lets the engine power to be fully applied to P1.
A pressure regulated outlet from the priority valve is sent to the servo-valve, which sends it to the loader valve service spools as control inputs. When the servo-control valve is operated it causes the selected service valve spool in the loader valve block to send the pressurised oil from the pumps to the selected service ram. The pressurised oil forces the piston along the bore to give a service movement. As the piston moves, the oil is pushed from the opposite end of the ram and returns to the tank through a filter.
The relief valves in the system prevent undue pressure increases through internal and external sources.
When the valve blocks are assembled, tighten the tie-rods to 67 lbf ft (91 Nm).
The main components of the 416 Wheeled Loader hydraulic system are the pump, loader valve block, priority valve, servo valve, steering valve, tank, rams and filters.
For descriptions of the steering and brake valves, refer to the relevant Sections.
A separate gear pump supplies the brake circuit.
The variable flow piston pump is driven by the engine and delivers pressurised oil to the priority valve section of the loader valve block. The priority valve ensures that the steering circuit has first demand on pump flow and pressure. A pressure regulated outlet from the loader valve is routed to the servo valve which in turn is redirected to the loader valve service spools as control inputs.
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Pages from 9803-4150 – JCB Wheeled Loading Shovel 411, 416 Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Wheeled Loading Shovel 411, 416. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Wheeled Loading Shovel 411, 416 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
9803-4150 – JCB Wheeled Loading Shovel 411, 416 Service Manual.pdf

EXCERPT:
Service Manual
Wheeled Loading Shovel – 411, 416
Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Hydraulic Steering
Section K – Engine
…
Hand Pump
To pressure test and re-set the Auxiliary Relief Valve (ARV), service kit 892/00309 must be used.
The service kit comprises; a test block 62-1, a setting body 62-2 with adjusting pin 62-3, a special spanner 62-4 and an anti-cavitation lock out bung 62-5. ARV cartridge removal tool 892/00335 comprises: an extractor cap 62-11 and a ‘C’ washer 62-12.
Fig 62.
1 Remove the complete ARV assembly from the excavator valve block. If the ARV sub-assembly 63-7 remains in the valve block, proceed as follows:
a Fit extractor cap 63-11 over the ARV subassembly 63-7, into the excavator valve block 63-E.
b Fit ‘C’ washer 63-12 on top of the extractor cap, but under the anti-cavitation spring seat as shown.
c Unscrew the extractor cap, – the ARV subassembly will withdraw with the extractor cap.
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Pages from 9813-1050 – JCB 430ZX Wheeled Loader Shovel Service Manual

Complete workshop & service manual with electrical wiring diagrams for JCB Wheeled Loader 410, 412, 415, 420, 425, 430, 430Z, 430ZX. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This JCB Wheeled Loader 410, 412, 415, 420, 425, 430, 430Z, 430ZX service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILELIST:
550-42385 – JCB 430Z Wheeled Loader Shovel Service Manual.pdf
9803-4100 – JCB 410, 412, 415, 420, 425, 430 Wheeled Loader Service Manual.pdf
9813-1050 – JCB 430ZX Wheeled Loader Shovel Service Manual.pdf

EXCERPT:
Service Manual
WLS 430ZX
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 – Steering
…
Cooling-Pack
Introduction
This is a combination pack, which supplies all the necessary cooling functions for the machines components with the exception of the ACU. (Most machines have air conditioning, but it is optional. Its installation or not does not make a difference to the function of the main cooling – pack.)
When viewed from the engine side A, the individual sections of the cooling-pack are:
– 1 Turbo Intercooler.
– 2 Transmission Oil Cooling.
– 3 Engine Coolant Radiator.
– 4 Hydraulic Oil Cooling.
The top and bottom holding-plates B and C hold the cooling-pack sections together.
Remove the section bolts 5 and 6, to remove and replace a single section. K Removal and Installation ( T B-16))
Fig 22.
7 Coolant drain plug.
8 The cooling-packs lower mounting points.
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