JCB 407B ZX, 408B ZX, 409B Z, 410B ZX, 411B ZX Wheel Loading Shovel Repair Service Manual

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This service manual PDF download for the 407B ZX, 408B ZX, 409B Z, 410B ZX, 411B ZX JCB Wheel Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Wheel Loading Shovel
407B, 408B, 409B, 410B, 411B - from S/N: 755000 Onwards
407B, 408B, 409B - from S/N: 1136000 Onwards

JCB Wheel Loading Shovel 407B ZX - from S/N: 755000 Onwards & S/N 1136000 Onwards
JCB Wheel Loading Shovel 408B ZX - from S/N: 755000 Onwards & S/N 1136000 Onwards
JCB Wheel Loading Shovel 409B Z - from S/N: 755000 Onwards & S/N 1136000 Onwards
JCB Wheel Loading Shovel 410B ZX - from S/N: 755000 Onwards
JCB Wheel Loading Shovel 411B ZX - from S/N: 755000 Onwards


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/4210-08
Total Pages : 451


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

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9803-4210-8

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

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

Section 3 - Maintenance
Maintenance
Routine Maintenance
Lubricants and Capacities
Lubricants and Capacities - North America
Lubricants and Capacities - (410B ZX, 411B ZX)
Lubricants and Capacities - (407 - 409B ZX)
Lubricants and Capacities - North America (407 - 409B ZX)
Lubricants and Capacities - (410B ZX, 411B ZX)
Lubricants and Capacities - North America (410B ZX, 411B ZX)
Health and Safety
Lubricants
Battery
First Aid - Electrolyte
Service Schedules
Greasing
Loader Arm Pivot Points
Articulation Joint
Propshaft and Steering Ram
Articulation Joint and Steering Rams (410B ZX, 411B ZX)
Propshafts (410B ZX, 411B ZX)
Articulation Lock
Installing the Articulation Lock
Removing the Articulation Lock
Loader Arm Safety Strut
Installing the Safety Strut
Removing the Safety Strut
Hydraulic System
Checking the Fluid Level
Changing the Filter Element (407 - 409B ZX, to S/N. 757399)
Checking the Hydraulic Oil Filter Pressure
Checking the Fluid Level (410B ZX, 411B ZX)
Changing the Filter Element (410B ZX, 411B ZX, 407 - 409B ZX S/N. 757400 on)
Refilling the Hydraulic System
Transfer Gearbox
Checking the Oil Level
Changing the Oil and Filter
Front and Rear Axles
Checking the Differential Oil Level
Draining and Refilling the Differential Oil
Checking the Hub Oil Level
Draining and Refilling the Hub Oil
Checking the Oil Level (410B ZX, 411B ZX)
Changing the Oil (410B ZX, 411B ZX)
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Fuel System
Types of Fuel
Draining the Fuel Filter
Changing the Fuel Filter Element
Draining the Sedimenter Bowl
Cleaning the Sedimenter Bowl
Bleeding the Fuel System
Cooling System
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Alternator Drive Belt
Adjusting the Drive Belt
Cab Heater Filter
Cleaning the Cab Heater Filter
Checking the Brake Fluid Level - 407B ZX to 409B ZX (Inching Fluid Level - 410/ 411B ZX)
Testing the Parking Brake
Ratchet Type
Over-Centre Type
Engine Air Filter
Changing the Elements (407 - 409B ZX to S/N. 757399)
Changing the Elements (407 - 409B ZX S/ N. 757400 on, 410B ZX, 411B ZX)
Wheels and Tyres
Tyre Pressures
Inflating the Tyres
Checking the Wheelnut Torques

Section B - Body and Framework
Body and Framework
Cab
Glazing
Direct Glazing
ROP/FOPS Structure
Checking
Removal and Replacement
Removal
Replacement
Service Procedures
Rivet Nuts
Fitting Procedure
Quickhitch
Dismantling and Assembly
When Dismantling
When Assembling
Loader Arms
Removal and Replacement
Removal
Replacement
Pivot Seal Fitting
Articulated Joint
Removal and Replacement
Prepare the Machine
Separating the Machine Halves
Inspecting the Articulated Joint
Renewing the Bushes

Section C - Electrics
Electrics
Technical Data
General Electrical Data
Oil Cooler Fan Motor
Fuses
Relays
Fuses
Relays
410B ZX to Serial No. 755490
Fuses
Relays
Fuse Box Decal
411B ZX, (410B ZX from Serial No. 755491), (407B ZX to 409B ZX from Serial No. 755491 to 757099)
Fuses
Relays
Fuse Box Decal
(407B ZX to 409B ZX from Serial No. 757100)
Fuses
Relays
Fuse Box Decal
Test Methods
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Service Procedures
Battery
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Starter Motor
Removal and Replacement
Dismantling, Servicing and Renewal and Assembly
Dismantling
Servicing and Renewal
Assembly
Circuit Diagrams
Machines To Serial No. 755182
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Machines From Serial No. 755183
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
410B ZX to serial number 755490
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
411B ZX (410B ZX from Serial No. 755491), (407B ZX to 409B ZX from Serial No. 755491 to 757099)
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
407B ZX to 409B ZX from Serial No. 757100
Main Components
Lamps
Fuses
Main Components
Lamps
Fuses
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Mainframe Harness - 407B ZX, 408B ZX, 409B ZX from Serial No. 757100
Cab Harness - 407B ZX, 408B ZX, 409B ZX from Serial No. 757100
Front Chassis Harness - 407B ZX, 408B ZX, 409B ZX from Serial No. 757100
Mainframe Harness - 410B ZX, 411B ZX from Serial No. 757600
Cab Harness - 410B ZX, 411B ZX from Serial No. 757600

Section E - Hydraulics
Hydraulics
Technical Data
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX, 411B ZX with optional Quick-hitch
Transmission Pump
Main Hydraulic Pump
Fan Pump
Steer Pump
Fan Motor
Transmission Motor
Valve Block
Relief Valve Operating Pressures
By-pass Pressures
Capacities
Rams
411B ZX with optional Quick-hitch
Circuit Diagrams
Servo (408B ZX, 409B ZX, to S/N. 757099)
Component Key
Manual (408B ZX, 409B ZX, to S/N. 757099)
Component Key
Servo (407B ZX, 408B ZX, 409B ZX, S/N. 757100 on)
Component Key
410B ZX (to S/N 757599)
Component Key
411B ZX (to S/N 757599)
Component Key
Manual (407B ZX, 408B ZX, 409B ZX from S/N 757100)
Component Key
410B ZX (from S/N 757600)
Component Key
411B ZX (from S/N 757600)
Component Key
Pressure Testing
Main Relief Valves (407B ZX, 408B ZX, 409B ZX)
Loader Valve
Steer Relief Valve
Servo Pressure
Main Relief Valves (410B ZX, 411B ZX)
Loader Valve
Servo Pressure
Auxiliary Relief Valves - Using Hand Pump
410B ZX, 411B ZX Machines
Transmission Setup (408B ZX, 409B ZX, to S/N. 757099, 410B ZX, 411B ZX)
Recommended Settings
Pump to Motor Connections
Pump Fwd/Rev Solenoid Connections
Speed Controller Setup
Transmission Setup (407B ZX, 408B ZX, 409B ZX S/N M757100 on)
Start-Up Procedure
Pressure Testing
Pumps
Transmission Pump (407B ZX, 408B ZX, 409B ZX to Serial No. 757099)
Removal and Replacement
Transmission Pump and Main Hydraulic Pump (407B ZX, 408B ZX, 409B ZX from Serial No. 757100 on)
Removal and Replacement
Transmission Pump, Main Hydraulic Pump and Fan Pump (410B ZX, 411B ZX)
Removal and Replacement
Transmission Pump, Main Hydraulic Pump and Fan Pump (410B ZX)
Pump/Engine Coupling
Main Hydraulic Pump (407B ZX, 408B ZX, 409B ZX to Serial No. 757099)
Removal and Replacement
Dismantling and Assembly
Main Hydraulic Pump (407B ZX, 408B ZX, 409B ZX from Serial No. 757100 on)
Dismantling and Assembly
Main Hydraulic Pump and Fan Pump (410B ZX, 411B ZX)
Removal and Replacement
Dismantling and Assembly
Fan Pump (407B XZ, 408B ZX, 409B ZX), Fan Motor (407 - 408B ZX to Serial No. 757099) Steer Pump (410B ZX, 411B ZX)
Pump Removal and Replacement
Fan Motor Removal and Replacement
Fan Pump (407B ZX, 408B ZX, 409B ZX) and Steer Pump (410B ZX 411B ZX)
Dismantling and Assembly
Fan Motor
(407B ZX, 408B ZX, 409B ZX, to S/N. 757099)
Dismantling and Assembly
(407B ZX, 408B ZX, 409B ZX, S/N 757100 on)
Removal and Replacement
(410B ZX, 411B ZX)
Removal and Replacement
(407B ZX, 408B ZX, 409B ZX, S/N 757100 on, 410B ZX, 411B ZX)
Dismantling and Assembly
Transmission Drive Motor
Removal and Replacement (407B ZX, 408B ZX, 409B ZX, To Serial No. 757099)
Removal
Replacement
Removal and Replacement (407B ZX, 408B ZX, 409B ZX, From Serial No. 757100 on)
Removal
Replacement
Removal and Replacement (410B ZX, 411B ZX)
Removal
Replacement
Control Valve
Removal and Replacement (407B ZX, 408B ZX, 409B ZX)
Removal
Replacement
Removal and Replacement (407B XZ, 408B ZX, 409B ZX)
Removal
Replacement
Rams
Typical Ram
Typical Ram
Fault Finding
Hydrostatic Pump
Hydrostatic Motor
Smooth Ride System
Technical Data
Accumulator Charge Pressures
Pressure Switch
Description
Circuit Descriptions
Wiring Harness
Electrical Schematic
Fault Finding
Charging/Discharging the Accumulator
Charging
Discharging
Accumulator
Removal and Replacement
Accumulators
Dismantle
Inspection
Assembly

Section F - Transmission
Transmission
Towing Procedure
Preparation
Preparation of the Transmission Pump for Towing - Type 1 Pump
Preparation of the Transmission Pump for Towing - Type 2 Pump
Preparation for Towing
Technical Data
407B ZX, 408B ZX, 409B, 410B ZX, 411B ZX
Axles
Transmission Pump
Transmission Motor
Transfer Box
Types Sizes
Axles
Front Axle
Removal
Replacement
Rear Axle (407B ZX, 408B ZX, 409B ZX)
Removal
Replacement
Rear Axle - 410B ZX, 411B ZX
Removal
Replacement
Drive Head - Front Axle
Removal and Replacement
Dismantling and Assembly
Drive Head - Rear Axle
Removal and Replacement
Dismantling and Assembly
Crown Wheel and Pinion
Adjustment
Correct Tooth Marking
Pinion too Deeply in Mesh
Pinion too Far Out of Mesh
Drive Head/Transfer Gearbox Oil Seal
Removal and Replacement
Drive Head (Maxtrac)
Dismantling and Assembly
Renewing the Pinion Oil Seal - Front Axle
Axle Hub and Driveshaft (407B ZX, 408B ZX, 409B ZX)
Dismantling and Assembly
Axle Hub and Driveshaft (410B ZX)
Dismantling and Assembly
Front and Rear Axles - 411B ZX
Hubs, Driveshafts and Brakes
Fault Finding
Transmission
Transfer Gearbox
Removal and Replacement (407B ZX, 408B ZX, 409B ZX)
Removal
Replacement
Removal and Replacement (411B ZX)
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly

Section G - Brakes
Brakes
Steering/Accumulator Charge Valve (411B ZX)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Service Brake
Removal and Replacement
Removal
Replacement
Bleeding
Dismantling and Assembling
Checking and Renewing the Brake Pads
Bleeding Procedure
411B ZX
Parking Brake
Removal and Replacement
Removal
Replacement
Dismantling and Assembling
Dismantling
Assembling
Checking and Renewing the Brake Pads
Adjusting the Brake Cable
Brake System Pressure Testing
(411B ZX)
Steering/Accumulator Charge Valve Operation
Accumulator Pressure
Technical Data
411B ZX

Section H - Hydraulic Steering
Hydraulic Steering
Technical Data
407B ZX, 408B ZX, 409B ZX, 410B ZX, 411B ZX
Steering Unit
Removal and Replacement
Removal
Replacement
Hydraulic Steering Unit (407B ZX, 408B ZX, 409B ZX)
Dismantling and Assembly
Dismantling
Assembling
Pressure Relief Valve Cartridge
Shock Valves
Hydraulic Steering Unit (410B ZX, 411B ZX)
Dismantling
Assembling
Steering Priority Valve
(410B ZX)
Removal and Replacement
Pressure Testing
(410B ZX)
(411B ZX)

Section K - Engine
Engine
Technical Data
1000 Series
411B ZX
New 1000 Series

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