Title: JCB 411HT, 413S, 417HT Wheel Loader Service Repair Manual Instant Download
1Foreword
SERVICE MANUAL 411HT, 413S, 417HT EN -
9813/2850 - ISSUE 3 - 11/2016 This
manual contains original instructions, verified
by the manufacturer (or their authorized
representative). Copyright 6-06-17 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
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, Ventilating Conditioning (HVAC) 15
- Engine
and Air-
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
218 - Fuel and Exhaust System 24 - Exhaust 00 -
General
00 - General
Introduction
Introduction .....................................
............... 18-71 Health and Safety
..........................................
18-72 Check (Condition) ..........................
................ 18-72
The exhaust system is used to guide exhaust gases
away from the controlled combustion inside the
engine by means of an exhaust pipe. Depending on
the machine design, the exhaust gas may flow
through the following components
- Cylinder head and exhaust manifold.
- Turbocharger to increase the engine power (if
installed). - A catalytic converter or EGR (Exhaust Gas
Recirculation) system to reduce air pollution (if
installed). - SCR (Selective Catalytic Reduction) (if
installed). In SCR system exhaust gases pass
through the DEF (Diesel Exhaust Fluid) injection
chamber to lower the NOx (Nitrogen Oxide)
concentration in the exhaust gases. - A silencer or muffler to reduce noise (if
installed). - The exhaust pipe carries the toxic and noxious
gases away from the users of the machine. Note
machines or generators that work indoors can
quickly fill an enclosed space with carbon
monoxide or other poisonous exhaust gases if
they are not properly vented to the outdoors.
18 - 71
9813/2850-3
18 - 71
318 - Fuel and Exhaust System 24 - Exhaust 00 -
General
Health and Safety Exhaust Gases Machine exhaust
gases can harm and possibly 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. Sparks Explosions and fire can be
caused by sparks from the exhaust or the
electrical system. Do not use the machine in
closed areas where there is flammable material,
vapour or dust. Hazardous Atmospheres This
machine is designed for use in normal out door
atmospheric conditions. It must not be used in
an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or
dust, without first consulting your JCB
dealer. Hot Components Touching hot surfaces can
burn skin. The engine and machine components
will be hot after the unit has been running.
Allow the engine and components to cool before
servicing the unit. WARNING! The engine has
exposed rotating parts. Switch off the engine
before working in the engine compartment. Do not
use the machine with the engine cover open.
Check (Condition)
Excessive smoke from the exhaust stack combined
with a complaint of low power could be as a
result of
- Dirt or dust (unfiltered air) ingested directly
into the engine, resulting in damage to the
cylinder bores, there will also be a possible
increase in oil consumption. - Air leaks from the air hose connections.
- Exhaust manifold leaks.
18 - 72
9813/2850-3
18 - 71
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518 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
03 - Inlet Manifold
Introduction
Introduction .....................................
............... 18-73 Component Identification
............................... 18-74 Check
(Condition) ......................................
.... 18-74 Remove and Install ....................
................... 18-75
The inlet manifold (or intake manifold) supplies
combustion air to the cylinders in compression
ignition engines or the air/fuel mixture for
spark ignition engines (except most direct
injection spark ignition engines). Even
distribution of the air or air/fuel is important
to optimize the efficiency and performance of
the engine.
The manifold is required to be air tight under
pressure and vacuum conditions and can be
required to provide mounting points for sensors,
grid heaters, throttle bodies and other
components depending on the engine type and
specification.
618 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
Component Identification
Check (Condition)
Figure 344.
- Check the manifold mating faces for signs of
damage and distortion. - Check the manifold casting for signs of cracks.
- Renew the manifold if there are any signs of
defect.
1 1 Inlet Manifold
718 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
Remove and Install
Before Removal
- Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work. - Get access to the engine.
- Remove the fuel rail assembly. Refer to (PIL
18-18).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
Figure 345.
7
6
11
12
10
8
13
9
3 3
4 5
1
2
1 Inlet manifold 2 Manifold gasket
3 Flanged hexagon bolt (x8) 4 Fuel rail mount
5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube
7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not
shown)
9 Throttle O-ring 10 Flanged hexagon bolt (x4)
11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)
13 Bolt M8 x 25mm (x1)
Remove
- Cap the inlet ports with blanking caps to prevent
ingress of dirt. - Inspect the manifold, refer to Check Condition
(PIL 18-24).
- Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector. - Disconnect the air inlet hose.
- Remove the bolts 3 and lift the inlet manifold
from the cylinder head. Discard the gasket.
818 - Fuel and Exhaust System 24 - Exhaust 03 -
Inlet Manifold
- Install
- The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps. - Renew the manifold gasket.
- Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the
two bolts (one at each end). - With the manifold and gasket in position, install
the remaining six bolts. - Tighten the bolts to the correct torque value.
- Table 148. Torque Values
Item Nm
3 43
918 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
04 - Outlet Manifold
Introduction
Introduction .....................................
............... 18-77 Component Identification
............................... 18-78 Check
(Condition) ......................................
.... 18-78 Remove and Install ....................
................... 18-79
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and deliver it
to the turbocharger (if installed) or the
exhaust pipe.
1018 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
Component Identification
Check (Condition)
Figure 346. A
- Check the manifold mating faces for signs of
damage and distortion. - Check the manifold casting for signs of cracks.
- Renew the manifold if there are any signs of
defect. - Visually inspect for leaks at the exhaust
manifold. Make sure all gaskets are in good
condition, replace as required.
B
- Exhaust manifold
- Manifold gasket and heat shield
1118 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
Remove and Install
Before Removal
- Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work. - Get access to the engine.
- Disconnect the oil pipes to the turbocharger,
refer to (PIL 18-36).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
Figure 347.
3
2
1
1 Exhaust manifold 3 Manifold gasket
2 Fixing bolts M10 x 57mm (x8)
Remove
- Renew the manifold gasket.
- Install the lower four bolts, together with the
new exhaust gasket to the cylinder head (screw
in the bolts approximately to a length of 8 mm). - Rest the manifold in position on the row of
lower bolts by locating the slots, then install
the remaining four upper bolts. - Tighten the bolts to the correct torque value.
Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
- Remove the upper four bolts.
- Loosen the lower four bolts and lift the exhaust
manifold from the cylinder head. Remove the
bolts and discard the gasket. - Cap the exhaust ports to prevent ingress of dirt.
- Inspect the manifold, refer to Check Condition
(PIL 18-24).
Install 1. The installation procedure is the
opposite of the removal procedure. Additionally
do the following steps.
After Installation 1. Reconnect the oil pipes to
the turbocharger (if installed).
1218 - Fuel and Exhaust System 24 - Exhaust 04 -
Outlet Manifold
- Install the exhaust pipe and the silencer box.
- Start the engine and check for exhaust leaks.
- Table 149. Torque Table
Item Torque Value (Nm) Torque Angle (Degrees)
2 (First Stage) 25
2 (Final Stage) 90
1318 - Fuel and Exhaust System 35 - Turbocharger 00
- General
00 - General
Introduction
Introduction .....................................
............... 18-95 Component Identification
............................... 18-96 Operation
..................................................
..... 18-97 Check (Condition) ....................
...................... 18-97 Check (Operation)
.........................................
18-98 Remove and Install .........................
.............. 18-99
The turbocharger (turbo) is a turbine driven
forced induction device that makes an engine
more efficient and helps to produce more power
for its size.
Engine exhaust gasses drive a turbine, which in
turn drives a compressor via a common shaft. The
shaft bearings are lubricated by a feed from the
engine lubrication system.
A turbocharged engine is more powerful and
efficient than a naturally aspirated engine
because the turbine forces more air, and
proportionately more fuel, into the combustion
chamber than atmospheric pressure alone.
9813/2850-3
18 - 100
1418 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Component Identification
Figure 357.
7.5
1 9
7.3,4
7.4
7
12
7.2
8
2
11
7.3,13 3
6
8.8 5
1 Turbocharger 3 Oil feed pipe (turbo
bearing) 5 Oil drain pipe (turbo bearing) 7 Pipe
adaptor (oil drain connection) 11 Pipe
clip 13 Banjo bolts M16
2 Exhaust manifold 4 Banjo bolts M12 6 Fixing
bolts (x2) 8 Retaining nuts (x4) 12 Bolt - pipe
adaptor ( oil drain connection)
9813/2850-3
18 - 100
1518 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Operation
Check (Condition)
- Visually inspect for leaks at the turbocharger.
Make sure all gaskets are in good condition,
replace as required. - Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced. - Make sure that the oil feed pipe and oil drain
pipe are clear and free from debris and sludge. - Check the turbine shaft running clearance.
- Place the stylus of a DTI (Dial Test Indicator)
against the shaft. - Move the shaft sideways.
- Figure 358.
The single stage exhaust turbocharger is
installed on this machine. On this turbocharger
the electronically controlled wastegate valve
controls the charge air pressure. The
electronically controlled wastegate valve does
the following functions
- It permits the adjustment of optimum charge air
pressure throughout the full load range - It takes other system factors into account which
influence the exhaust gas and charge air flow.
These are mentioned below
- exhaust gas recirculation
- charge-air cooling
- exhaust brake
- temperature and pressure of intake air
- fuel injection data
It improves the engine torque characteristics
- across the full engine speed range, particularly
for low engine speeds - It reduces fuel consumption
- It reduces pollutant emissions
- 4.3. Make sure that the turbine shaft running
clearance is within the specified limits. Refer
to Turbocharger, Technical Data (PIL 18-35). - Check the shaft end float.
- Place the stylus of the DTI against the end of
the shaft.
9813/2850-3
18 - 100
1618 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Check (Operation)
Figure 359.
To maximise the duration of the turbocharger
follow the rules described below. Start-up Start
the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached
within a few seconds, but it is useful to allow
the moving parts to warm up in good lubrication
conditions. Immediately increasing the engine
speed after start up will result in the
turbocharger running at high rpm with less than
optimal lubrication. This may lead to premature
failure of the turbocharger.
After maintenance When carrying out maintenance
on the engine or turbocharger, pre-lubricate the
oil inlet of the turbocharger by adding clean
lubricant until it is completely full. After
pre-lubrication, let the engine run via the
starter motor without firing (engine / fuel pump
stop out) to allow the oil to circulate through
the complete system under pressure. Upon engine
start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to
work satisfactorily.
- Move the shaft axially.
- Make sure that the shaft end float is within the
specified limits. Refer to Turbocharger,
Technical Data (PIL 18-35).
Low temperature air or engine inactivity If the
engine has been inactive for a certain period of
time or the air temperature is very low, start
the engine and then let it run at idle speed.
This enables the oil to go into the lubrication
system before applying high loads and speeds to
the engine and turbocharger. Engine
shutdown Before switching the engine off after
intense activity, you must allow the
turbocharger to cool down, let the engine run at
idle speed for at least 2 minutes to allow the
turbocharger to cool. Engine at idle speed Avoid
running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation
leads to low pressure values in the
turbocharger, which may cause oil leaks from the
seals at the ends of the turbo bearing shaft.
Even if this does not cause damage, it can cause
blue smoke from the exhaust when the engine
speed and load are increased.
9813/2850-3
18 - 100
1718 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Remove and Install
Figure 360.
7.5
1 9
7.3,4
7.4
7
12
7.2
8
2
11
7.3,13 3
6
8.8 5
1 Turbocharger 3 Oil feed pipe (turbo
bearing) 5 Oil drain pipe (turbo bearing) 7 Pipe
adaptor (oil drain connection) 11 Pipe
clip 13 Banjo bolts M16 Before Removal
2 Exhaust manifold 4 Banjo bolts M12 6 Fixing
bolts (x2) 8 Retaining nuts (x4) 12 Bolt - pipe
adaptor ( oil drain connection)
- Get access to the engine.
- Drain the cooling system.
- This procedure requires service parts. Make sure
you have obtained the correct parts before you
start, refer to Parts Catalogue. - Make sure that the engine is safe to work on. If
the engine has been running, make sure the
engine has cooled sufficiently before you start. - Remove the ignition key.
Remove
- Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose. - Remove the pipe clip. Undo fixing bolts and
remove the oil drain pipe. Note that the pipe
pulls
9813/2850-3
18 - 100
1818 - Fuel and Exhaust System 35 - Turbocharger 00
- General
- off the pipe adaptor, leaving the adaptor in
place. Cap the open ports to prevent ingress of
dirt. Discard the O-ring and the gasket. - Undo the banjo bolts at each end of the oil feed
pipe, remove the pipe. Cap the open ports to
prevent ingress of dirt. Discard the sealing
washers. - Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold-Removal and
Replacement. Discard the exhaust manifold
gasket. - With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket. - If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard the gasket. - Install
- The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps. - Check the condition of the turbocharger (PIL
18-35) - Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important not to run the
new turbo dry. - Renew all O' rings, sealing washers and
gaskets. - Note that the exhaust manifold gasket also
functions as a heat shield. Be sure to position
the gasket the correct way round. - Tighten the nuts, bolts and banjo bolts to the
correct torque value. - Table 152. Torque Values
Item Nm
4 21
6 24
8 24
13 36
9813/2850-3
18 - 100
1918 - Fuel and Exhaust System 35 - Turbocharger 03
- Actuator
03 - Actuator Introduction The turbocharger
actuator is used for the electronic charge air
pressure regulation. The turbocharger actuator
is also called the charge pressure
regulator. The ECM (Engine Control Module) sends
a signal to the turbocharger actuator to actuate
the charge air pressure flap (wastegate valve)
and through a mechanical linkage turbocharger
actuator operates the charge air pressure flap
(wastegate valve). Depending on the flap
position, either the entire exhaust gas is
routed to the turbine or part of the exhaust gas
is routed to the exhaust pipe upstream of the
turbine. The turbocharger actuator is cooled with
coolant.
9813/2850-3
18 - 100
2018 - Fuel and Exhaust System 96 - Fuel Pipe 00 -
General
Health and Safety WARNING Do not open the high
pressure fuel system with the engine running.
Engine operation causes high fuel pressure. High
pressure fuel spray can cause serious injury or
death. Notice Do not allow dirt to enter the
fuel system. Before disconnecting any part of
the fuel system, thoroughly clean around the
connection. When a component has been
disconnected, for example a fuel pipe, always
fit protective caps and plugs to prevent dirt
ingress. Failure to follow these instructions
will lead to dirt entering the fuel system. Dirt
in the fuel system will seriously damage the
fuel injection equipment and could be expensive
to repair.
9813/2850-3
18 - 114
2118 - Fuel and Exhaust System 96 - Fuel Pipe 00 -
General
Component Identification
Figure 369.
A
A
A
A
B
F
E
G
A Pipe assembly high pressure - Rail to injector
(x4) C Pipe low pressure - Fuel lift pump and
pre-filter/ water separator (not shown) E Pipe
assembly low pressure - Fuel injectors to tank G
Pipe low pressure - Return to tank
B Pipe assembly high pressure - Pump to rail
D Pipe low pressure - Fuel filter to high
pressure pump (not shown) F Pipe assembly low
pressure - Rail to tank
9813/2850-3
18 - 114
2218 - Fuel and Exhaust System 96 - Fuel Pipe 00 -
General
Preparation
Important Before you disconnect or remove fuel
pipes make sure that you have the correct new
parts. The high pressure fuel pipes MUST BE
REPLACED with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a
bag is open DO NOT USE the fuel pipe, get a new
one.
- must decay before you start work. If the engine
has been running, wait at least one hour before
you start work. - Clean the engine. Refer to Engine-Clean (PIL
15-00). - Remove the protective cover. Push out the four
plastic segments. Remove the screws and lift off
the cover. - Remove any dirt or debris that is exposed. Refer
to Engine-Clean (PIL 15-00).
Obey all fuel system health and safety
information. Refer to (PIL 18-00).
1. Make sure that the engine is safe to work
on. The engine must cool and pressure in the
fuel system
Figure 370.
A Protective cover C Screws
B Plastic segments (x4)
9813/2850-3
18 - 114
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2418 - Fuel and Exhaust System 96 - Fuel Pipe 03 -
High Pressure Pipe
03 - High Pressure Pipe Remove and
Install Special Tools
- Use the 17mm deep socket special tool at the top
of nut. This will prevent damage to the nut. - Special Tool Socket 17MM Offset - (HP Fuel
pipes) (Qty. 1) - Special Tool Torque Wrench (10-100Nm) (Qty. 1)
- Loosen the nut C. Do not remove the nut at this
step. - Figure 373.
Description Part No. Qty.
Socket 17MM Offset - (HP Fuel pipes) 331/27987 1
Torque Wrench (10-100Nm) 993/70111 1
Injector Fuel Pipes
F
- Remove
- The procedure describes how to remove one fuel
pipe. - Remove the fuel pipes one at a time.
C
Figure 371.
E
B
D
- Nut
- Nut
- Fuel pipe
- Fuel pipe
- Push the fuel pipe against the injector cone and
at the same time remove the nut B. - Push the fuel pipe against the rail cone and at
the same time remove the nut C. - Make sure that there is no dirt or debris on the
fuel pipe or the connectors. - Remove the fuel pipe.
- Seal all the open ports, use the correct parts
from the service kit. - Repeat step 1 to remove the other fuel pipes.
- Discard the old fuel pipes.
D Fuel pipe 1.2. Put an open ended spanner at the
top of nut (This will prevent damage to the
nut). Loosen the nut (Do not remove the nut at
this step). Figure 372.
- Install
- Important The high pressure fuel pipes must be
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a
bag is open do not use the fuel pipe, get a new
one. Do not open the bag until you are ready to
assemble the fuel pipe. - Make sure that the bleed-off adaptors are
assembled on the injectors before you install the
high pressure pipes. - Assemble the fuel pipes one at a time. The
procedure describes how to assemble one fuel
pipe.
9813/2850-3
18 - 117
2518 - Fuel and Exhaust System 96 - Fuel Pipe 03 -
High Pressure Pipe
- Put the correct end of the fuel pipe against the
correct injector cone. - Tighten the nut B with your hand.
- Put the other end of the fuel pipe against the
correct rail cone. - Tighten the nut C with your hand. Nuts must be
tightened in the correct sequence. Tighten nut B
and then nut C. - Use the special tool at the top of nut B and
tighten it to the correct torque value. - Special Tool Socket 17MM Offset - (HP Fuel
pipes) (Qty. 1) - Put the spanner at the top of nut C and tighten
it to the correct torque value.
Figure 375.
B
Pump to Rail Fuel Pipes Remove
C
- To remove the fuel pipe.
- Put an open ended spanner at the top of nut
(This will prevent damage to the nut). Loosen
the nut (Do not remove the nut at this step). - Figure 374.
- A
- Nut
- Nut
- Fuel pipe
- Use the 17mm deep socket special tool at the top
of nut. This will prevent damage to the nut. - Special Tool Socket 17MM Offset - (HP Fuel
pipes) (Qty. 1) - Special Tool Torque Wrench (10-100Nm) (Qty. 1)
- Push the fuel pipe against the injector cone and
at the same time remove the nut B. - Push the fuel pipe against the rail cone and at
the same time remove the nut C. - Make sure that there is no dirt or debris on the
fuel pipe or the connectors. - Remove the fuel pipe.
1.2. Loosen the nut A. Do not remove the nut at
this step.
9813/2850-3
18 - 117
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