Jcb 411 ht, 413s, 417ht wheel loader service repair manual from 2094871 to 2095871

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
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, Ventilating and Air-
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

24 - Exhaust
00 - General
18 - 71 9813/2850-3 18 - 71
00 - General
Introduction .................................................... 18-71
Health and Safety .......................................... 18-72
Check (Condition) .......................................... 18-72
Introduction
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.

24 - Exhaust
00 - General
18 - 72 9813/2850-3 18 - 72
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.

24 - Exhaust
03 - Inlet Manifold
18 - 73 9813/2850-3 18 - 73
03 - Inlet Manifold
Introduction .................................................... 18-73
Component Identification ............................... 18-74
Check (Condition) .......................................... 18-74
Remove and Install ....................................... 18-75
Introduction
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.

24 - Exhaust
03 - Inlet Manifold
18 - 74 9813/2850-3 18 - 74
Component Identification
Figure 344.
1
1 Inlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.

24 - Exhaust
03 - Inlet Manifold
18 - 75 9813/2850-3 18 - 75
Remove and Install
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. 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.
3. Get access to the engine.
4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 345.
2
3
3
4
5
12
8
9
11 10
6
7
13
1
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
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector.
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
4. Cap the inlet ports with blanking caps to prevent
ingress of dirt.
5. Inspect the manifold, refer to Check Condition
(PIL 18-24).

24 - Exhaust
03 - Inlet Manifold
18 - 76 9813/2850-3 18 - 76
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.
5. Tighten the bolts to the correct torque value.
Table 148. Torque Values
Item Nm
3 43

24 - Exhaust
04 - Outlet Manifold
18 - 77 9813/2850-3 18 - 77
Introduction .................................................... 18-77
Check (Condition) .......................................... 18-78
Introduction
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and deliver it to the
turbocharger (if installed) or the exhaust pipe.

24 - Exhaust
18 - 78 9813/2850-3 18 - 78
Figure 346.
A B
A Exhaust manifold
B Manifold gasket and heat shield
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.

24 - Exhaust
18 - 79 9813/2850-3 18 - 79
Remove and Install
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. 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.
4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 347.
2
1
3
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)
3 Manifold gasket
Remove
1. Remove the upper four bolts.
2. Loosen the lower four bolts and lift the exhaust
manifold from the cylinder head. Remove the
bolts and discard the gasket.
3. Cap the exhaust ports to prevent ingress of dirt.
4. Inspect the manifold, refer to Check Condition
(PIL 18-24).
Install
steps.
2. Renew the manifold gasket.
3. 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).
4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
remaining four upper bolts.
5. Tighten the bolts to the correct torque value.
Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
After Installation
1. Reconnect the oil pipes to the turbocharger (if
installed).

24 - Exhaust
18 - 80 9813/2850-3 18 - 80
2. Install the exhaust pipe and the silencer box.
3. 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

35 - Turbocharger
00 - General
18 - 95 9813/2850-3 18 - 95
00 - General
Introduction .................................................... 18-95
Operation ....................................................... 18-97
Check (Condition) .......................................... 18-97
Check (Operation) ......................................... 18-98
Introduction
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.

35 - Turbocharger
00 - General
18 - 96 9813/2850-3 18 - 96
Figure 357.
7.3,47.4
7.5
12
7
7.3,13
2
8
7.2
3
6
8.8 5
1 9
11
1 Turbocharger 2 Exhaust manifold
3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16

35 - Turbocharger
00 - General
18 - 97 9813/2850-3 18 - 97
Operation
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
Check (Condition)
1. Visually inspect for leaks at the turbocharger.
Make sure all gaskets are in good condition,
replace as required.
2. 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.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways.
Figure 358.
4.3. Make sure that the turbine shaft running
clearance is within the specified limits.
Refer to Turbocharger, Technical Data (PIL
18-35).
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.

35 - Turbocharger
00 - General
18 - 98 9813/2850-3 18 - 98
Figure 359.
5.2. Move the shaft axially.
5.3. Make sure that the shaft end float is within
the specified limits. Refer to Turbocharger,
Technical Data (PIL 18-35).
Check (Operation)
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.
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.

35 - Turbocharger
00 - General
18 - 99 9813/2850-3 18 - 99
Remove and Install
Figure 360.
7.3,47.4
7.5
12
7
7.3,13
2
8
7.2
3
6
8.8 5
1 9
11
1 Turbocharger 2 Exhaust manifold
3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
Before Removal
1. This procedure requires service parts. Make sure
you have obtained the correct parts before you
start, refer to Parts Catalogue.
2. 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.
3. Remove the ignition key.
5. Drain the cooling system.
Remove
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose.
2. Remove the pipe clip. Undo fixing bolts and
remove the oil drain pipe. Note that the pipe pulls

35 - Turbocharger
00 - General
18 - 100 9813/2850-3 18 - 100
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.
3. 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.
4. 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.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket.
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard the gasket.
Install
steps.
2. Check the condition of the turbocharger (PIL
18-35)
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all `O' rings, sealing washers and
gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat shield. Be sure to position the
gasket the correct way round.
6. 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

35 - Turbocharger
03 - Actuator
18 - 101 9813/2850-3 18 - 101
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.

96 - Fuel Pipe
00 - General
18 - 114 9813/2850-3 18 - 114
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.

96 - Fuel Pipe
00 - General
18 - 115 9813/2850-3 18 - 115
Figure 369.
B
G
A
A
A
A
E
F
A Pipe assembly high pressure - Rail to injector
(x4)
B Pipe assembly high pressure - Pump to rail
C Pipe low pressure - Fuel lift pump and pre-filter/
water separator (not shown)
D Pipe low pressure - Fuel filter to high pressure
pump (not shown)
E Pipe assembly low pressure - Fuel injectors to
tank
F Pipe assembly low pressure - Rail to tank
G Pipe low pressure - Return to tank

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96 - Fuel Pipe
00 - General
18 - 116 9813/2850-3 18 - 116
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.
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
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine-Clean (PIL
15-00).
3. Remove the protective cover. Push out the four
plastic segments. Remove the screws and lift off
the cover.
4. Remove any dirt or debris that is exposed. Refer
to Engine-Clean (PIL 15-00).
Figure 370.
A Protective cover B Plastic segments (x4)
C Screws

96 - Fuel Pipe
03 - High Pressure Pipe
18 - 117 9813/2850-3 18 - 117
Remove and Install
Special Tools
Description Part No. Qty.
Socket 17MM Offset -
(HP Fuel pipes)
331/27987 1
Torque Wrench
(10-100Nm)
993/70111 1
Injector Fuel Pipes
Remove
1. The procedure describes how to remove one fuel
pipe.
1.1. Remove the fuel pipes one at a time.
Figure 371.
D
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.
1.3. 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)
1.4. Loosen the nut C. Do not remove the nut at
this step.
Figure 373.
B
C
E
F
B Nut
C Nut
E Fuel pipe
F Fuel pipe
1.5. Push the fuel pipe against the injector cone
and at the same time remove the nut B.
1.6. Push the fuel pipe against the rail cone and
at the same time remove the nut C.
1.7. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.8. Remove the fuel pipe.
1.9. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
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.
1. Make sure that the bleed-off adaptors are
assembled on the injectors before you install the
high pressure pipes.
2. Assemble the fuel pipes one at a time. The
procedure describes how to assemble one fuel
pipe.

96 - Fuel Pipe
18 - 118 9813/2850-3 18 - 118
2.1. Put the correct end of the fuel pipe against
the correct injector cone.
2.2. Tighten the nut B with your hand.
2.3. Put the other end of the fuel pipe against the
correct rail cone.
2.4. Tighten the nut C with your hand. Nuts
must be tightened in the correct sequence.
Tighten nut B and then nut C.
2.5. Use the special tool at the top of nut B and
tighten it to the correct torque value.
2.6. Put the spanner at the top of nut C and
tighten it to the correct torque value.
Pump to Rail Fuel Pipes
Remove
1. To remove the fuel pipe.
1.1. 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.
1.2. Loosen the nut A. Do not remove the nut at
this step.
Figure 375.
B
C
A
A Nut
B Nut
C Fuel pipe
1.3. Use the 17mm deep socket special tool at
the top of nut. This will prevent damage to
the nut.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
1.4. Push the fuel pipe against the injector cone
and at the same time remove the nut B.
1.5. Push the fuel pipe against the rail cone and
at the same time remove the nut C.
1.6. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.7. Remove the fuel pipe.

Jcb 411 ht, 413s, 417ht wheel loader service repair manual from 2094871 to 2095871

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Jcb 411 ht, 413s, 417ht wheel loader service repair manual from 2094871 to 2095871