jcb 419S, Service Manual

Page 1: ... You must understand and follow the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operator s Manual or if there is anything on the machine you do not understand Treat the Operator s Manual as part of the machine Keep it clean and in good condition Replace the Operator s Manual immediately ...

Page 2: ...9813 6500 1 Notes Find manuals at https best manuals com ...

Page 3: ...13 6500 1 SERVICE MANUAL Volume 1 419S EN 9813 6500 SERVICE MANUAL Volume 2 419S EN 9813 6500 SERVICE MANUAL Volume 3 419S EN 9813 6500 SERVICE MANUAL Volume 4 419S EN 9813 6500 Find manuals at https best manuals com ...

Page 4: ...Notes 9813 6500 1 Find manuals at https best manuals com ...

Page 5: ...fety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 19 01 06 06 Using the Manual 01 20 01 09 Description 01 09 12 Main Component Locations 01 23 01 09 15 Service Point Locations 01 24 01 33 Cleaning 01 33 00 General 01 29 Find manuals at https best man...

Page 6: ...9813 6500 1 2017 02 23 Acronyms Glossary FOPS Falling Object Protective Structure PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com ...

Page 7: ...ty Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 Find manuals at https best manuals com ...

Page 8: ...Notes 01 2 9813 6500 1 01 2 Find manuals at https best manuals com ...

Page 9: ... hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them Do not work with the machine until you are sure that you can control it Do not start ...

Page 10: ...tion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in machine damage The safety alert system shown also helps to identify important safety messages in this manual and on the mach...

Page 11: ...aware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switc...

Page 12: ...eer Hydraulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or r...

Page 13: ...ecomposition 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 571 6 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 Thoroughly wash contaminated area with 10 cal...

Page 14: ...ly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machin...

Page 15: ... s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Controls You or others can be killed or seriou...

Page 16: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Page 17: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Page 18: ...necessary empty the shovel 2 Make sure that the machine is parked correctly in the straight ahead position on solid level ground 3 Apply the park brake 4 Lower the lift arm and put the attachment flat on the ground 5 Stop the engine 6 Remove the ignition key 7 Put chocks on both sides of all the wheels 8 Remove the battery isolation key Refer to PIL 33 03 9 Install the articulation lock Refer to P...

Page 19: ... to install the maintenance struts 5 Run the engine at idle for a few minutes to let the turbocharger cool Duration 2 3min 6 Stop the engine 7 Remove the ignition key 8 Put chocks on both sides of all the wheels 9 Install the articulation lock Refer to PIL 06 27 10 Remove the maintenance struts from the tool box 11 Install the maintenance strut in correct position around the ram 12 Make sure that ...

Page 20: ...01 Machine 03 Safety 27 Maintenance Positions 01 14 9813 6500 1 01 14 C Strap 2 D Maintenance strut 2 ...

Page 21: ...fer to PIL 33 03 3 Start the engine 4 Raise the lift arm sufficiently to remove the weight from the maintenance struts 5 Stop the engine 6 Remove the ignition key 7 Remove the strap from the maintenance strut 8 Remove the maintenance strut 9 Start the engine 10 Lower the lift arm to the ground 11 Stop the engine 12 Put the maintenance strut in the tool box 13 Remove the articulation lock 14 Remove...

Page 22: ...must be correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not using electrical power If you do not take these precautions you could be killed or injured WARNING Make the machine safe before getting beneath it Make sure that any attachments on the machine are correctly attached Engage the park brake remove the ig...

Page 23: ...01 Machine 06 About this Manual 01 17 9813 6500 1 01 17 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 19 01 06 06 Using the Manual 01 20 ...

Page 24: ...Notes 01 18 9813 6500 1 01 18 ...

Page 25: ...out this Manual 03 Model and Serial Number 01 19 9813 6500 1 01 19 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 419S 2439651 ...

Page 26: ... Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls functions and use Refer to the applicable Operator Manual Check that the maintenance record complies with the applicable schedule for the operating environment Refer to PIL 78 24 Check that the fluid...

Page 27: ...01 Machine 09 Description 01 21 9813 6500 1 01 21 09 Description Contents Page No 01 09 12 Main Component Locations 01 23 01 09 15 Service Point Locations 01 24 ...

Page 28: ...Notes 01 22 9813 6500 1 01 22 ...

Page 29: ...re 5 C D E A B A F G H J L K A Loader arms B Quickhitch C ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure Cab D Engine cover E Hydraulic fluid filler point F Hydraulic fluid tank sight glass G Battery isolator H Battery cover J Diesel filler point K Articulation lock L Transmission filler point ...

Page 30: ...09 Description 15 Service Point Locations 01 24 9813 6500 1 01 24 15 Service Point Locations Introduction Figure 6 B C A E D G H J F A Engine fuel filter B Fuel filter C Engine oil dipstick D Engine oil filler cap ...

Page 31: ... filter G Washer bottle H Radiator J Coolant expansion tank Figure 7 A A Engine oil drain Figure 8 A B A Battery isolator B Battery compartment Figure 9 C D A B A Transmission oil filler point B Transmission oil level sight glass C Tank filler point blue D Fuel filler point Figure 10 A A Hydraulic level gauge ...

Page 32: ...01 Machine 09 Description 15 Service Point Locations 01 26 9813 6500 1 01 26 Figure 11 A A B C B D A Dipstick B Drain plug Output C Drain plug D Drain plug Optional ...

Page 33: ...01 Machine 33 Cleaning 01 27 9813 6500 1 01 27 33 Cleaning Contents Page No 01 33 00 General 01 29 ...

Page 34: ...Notes 01 28 9813 6500 1 01 28 ...

Page 35: ...render the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surroun...

Page 36: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe Stop the machine and let it cool for at least one hour Do not try to c...

Page 37: ...Acronyms Glossary 03 2 03 00 Attachments 03 00 00 General 03 3 03 09 Lift Arm Quickhitch 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 03 12 Hitch 03 12 12 Mechanical Tow 03 17 03 12 13 Hydraulic Tow 03 21 03 30 Shovel 03 30 00 General 03 31 03 33 Fork 03 33 15 Grass 03 35 ...

Page 38: ...9813 6500 1 2017 02 08 Acronyms Glossary HBCV Hose Burst Check Valve ...

Page 39: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 6500 1 03 1 00 Attachments Contents Page No 03 00 00 General 03 3 ...

Page 40: ...Notes 03 2 9813 6500 1 03 2 ...

Page 41: ...dients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic system mounting arrangements and safe load requirements Attachments which are not designed for use with this machine may cause damage and create safet...

Page 42: ...or s Manual do not install it use it or remove it until you have obtained read and understood the pertinent information Install attachments only on the machines for which they were designed WARNING Load and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and ...

Page 43: ...03 Attachments Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9813 6500 1 03 5 09 Lift Arm Quickhitch Contents Page No 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 ...

Page 44: ...Notes 03 6 9813 6500 1 03 6 ...

Page 45: ...f buckets shovels and other attachments on the machine Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations but when installed on a machine they become a part of the overall machine system They are usually mounted on the machine by means of pins that would otherwise be the mountings for the shovel or attachment ...

Page 46: ...ge the attachment If a second person is to be involved in this procedure make sure that they keep clear of the machine and attachment until signalled by you to proceed For more information on the servo control lever and the auxiliary controls A Quickhitch isolator valve is installed on all machines This valve can be used to hydraulically operate the locking pins to lock an attachment to the Quickh...

Page 47: ...connect and Connect Disengage the Attachment Figure 13 A A Locking pins 1 Park the machine on solid level ground 2 Engage the park brake and put the transmission in neutral 2 1 If necessary disconnect the hydraulic hoses 3 Push and hold the Quickhitch isolator switch 4 Disengage the locking pins Refer to Figure 13 4 1 Proportional lever control with an auxiliary button Push the auxiliary 1 button ...

Page 48: ...ver control option Move the lever forward and tilt the Quickhitch forward and lower the lift arm 7 When the pivot shaft has disengaged from the hooks reverse the machine clear Figure 16 A B A Hooks B Pivot shaft Engage the Attachment 1 Align the machine square with the attachment 2 Lower the lift arm until the pivot shaft is below the level of the hooks on the attachment Refer to Figure 17 Figure ...

Page 49: ...d dump C Auxiliary 1 D Auxiliary 2 option E Differential lock F Horn G Transmission kickdown switch H Forward reverse switch 7 Push and hold the quickhitch isolator switch 8 Engage the locking pins in the attachment 8 1 Proportional lever control with an auxiliary button Push the auxiliary 1 button until the locking pins are engaged 8 2 Multi lever control option Push the lever until the locking p...

Page 50: ...nts Couplings and Load Handling 09 Lift Arm Quickhitch 06 Hydraulic Quickhitch 03 12 9813 6500 1 03 12 Lubricate There are two greasing points for the lubrication of the quickhitch Refer to Figure 21 Figure 21 2 1 ...

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