jcb 419S Service Manual
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SERVICE MANUAL
LOADER
419S
EN - 9813/6500
ISSUE 1 - 02/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 7-02-20 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. 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 if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Table of Contents
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Summary of Contents for jcb 419S

  • Page 1 Operator's Manual. 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/6500-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 419S 419S EN 9813/6500 EN 9813/6500 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 419S 419S EN 9813/6500 EN 9813/6500 9813/6500-1 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/6500-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - 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 ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure Parts Identification List ROPS Roll-Over Protective Structure 9813/6500-1 2017-02-23 Find manuals at https://best-manuals.com...
  • Page 7: Safety

    01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - 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 ......................
  • Page 8 Notes: 01 - 2 9813/6500-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety - Yours And Others

    They inform you of potential 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.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause injury.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-16 maintenance procedure. You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Lift Arm Raised 5. Run the engine at idle for a few minutes to let the turbocharger cool. Figure 3. Duration: 2–3min 6. Stop the engine. 7. Remove the ignition key. 8.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions C Strap 2 D Maintenance strut 2 01 - 14 9813/6500-1 01 - 14...
  • Page 21 01 - Machine 03 - Safety 27 - Maintenance Positions Stow the Maintenance Struts 1. Make sure the park brake is engaged and the transmission is in neutral. 2. Install the battery isolation key. Refer to (PIL 33-03). 3. Start the engine. 4.
  • Page 22 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 23: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-19 01-06-06 Using the Manual ......................01-20 01 - 17 9813/6500-1 01 - 17...
  • Page 24 Notes: 01 - 18 9813/6500-1 01 - 18...
  • Page 25 01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 419S 2439651 01 - 19...
  • Page 26 06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 27 01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-23 01-09-15 Service Point Locations ....................01-24 01 - 21 9813/6500-1 01 - 21...
  • Page 28 Notes: 01 - 22 9813/6500-1 01 - 22...
  • Page 29 01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 5. A Loader arms B Quickhitch C ROPS (Roll-Over Protective Structure)/FOPS D Engine cover (Falling Object Protective Structure) Cab E Hydraulic fluid filler point F Hydraulic fluid tank sight glass G Battery isolator H Battery cover...
  • Page 30 01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Figure 6. A Engine fuel filter B Fuel filter C Engine oil dipstick D Engine oil filler cap 01 - 24 9813/6500-1 01 - 24...
  • Page 31 01 - Machine 09 - Description 15 - Service Point Locations E Hydraulic oil filler cap F Air filter G Washer bottle H Radiator J Coolant expansion tank Figure 7. Figure 9. A Engine oil drain Figure 8. A Battery isolator B Battery compartment A Transmission oil filler point B Transmission oil level sight glass...
  • Page 32 01 - Machine 09 - Description 15 - Service Point Locations Figure 11. A Dipstick B Drain plug - Output C Drain plug D Drain plug (Optional) 01 - 26 9813/6500-1 01 - 26...
  • Page 33 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-29 01 - 27 9813/6500-1 01 - 27...
  • Page 34 Notes: 01 - 28 9813/6500-1 01 - 28...
  • Page 35 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-29 or other chemicals, you must adhere to Preparation ............ 01-30 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 36 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 37 03 - Attachments, Couplings and Load Handling Contents Page No. 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 .........................
  • Page 38: Acronyms Glossary

    Acronyms Glossary HBCV Hose Burst Check Valve 9813/6500-1 2017-02-08...
  • Page 39: Attachments

    03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/6500-1 03 - 1...
  • Page 40 Notes: 03 - 2 9813/6500-1 03 - 2...
  • Page 41: General

    A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 42 00 - Attachments 00 - General Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
  • Page 43: Lift Arm Quickhitch

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03-09-06 Hydraulic Quickhitch ......................03-8 03 - 5 9813/6500-1 03 - 5...
  • Page 44 Notes: 03 - 6 9813/6500-1 03 - 6...
  • Page 45: General

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Quickhitches are used on machines to allow the rapid change of 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.
  • Page 46: Hydraulic Quickhitch

    03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Introduction WARNING If two people are doing this job make Introduction ............03-8 sure that the person working the controls is a Disconnect and Connect .........
  • Page 47 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Disconnect and Connect Figure 12. Disengage the Attachment Figure 13. A Locking pins 1. Park the machine on solid, level ground. A Locking pins 2.
  • Page 48 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Figure 14. 6.1. Proportional lever control: Move the lever to the right and tilt the Quickhitch forward and lower the lift arm. 6.2. Multi lever control option: Move the lever forward and tilt the Quickhitch forward and lower the lift arm.
  • Page 49 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Figure 18. 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 pins are engaged.
  • Page 50 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Lubricate There are two greasing points for the lubrication of the quickhitch. Refer to Figure 21. Figure 21. 03 - 12 9813/6500-1 03 - 12...
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