jcb 411HT, Service Manual

Page 1: ...al 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 Operat...

Page 2: ...9813 2850 3 Notes Find manuals at https best manuals com...

Page 3: ...Volume 1 411HT 413S 417HT EN 9813 2850 SERVICE MANUAL Volume 2 411HT 413S 417HT EN 9813 2850 SERVICE MANUAL Volume 3 411HT 413S 417HT EN 9813 2850 SERVICE MANUAL Volume 4 411HT 413S 417HT EN 9813 2850...

Page 4: ...Notes 9813 2850 3 Find manuals at https best manuals com...

Page 5: ...3 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 01 06 About this Manual 01 06 06 Using th...

Page 6: ...9813 2850 3 2016 10 07 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: ...y 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 Assessme...

Page 8: ...Notes 01 2 9813 2850 3 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...

Page 10: ...ion 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 N...

Page 11: ...are 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...

Page 12: ...er 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 Mak...

Page 13: ...dence of decomposition 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...

Page 14: ...r 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...

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...

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 runn...

Page 17: ...nd 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 wi...

Page 18: ...ecessary 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...

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...

Page 20: ...01 Machine 03 Safety 27 Maintenance Positions 01 14 9813 2850 3 01 14 C Strap 2 D Maintenance strut 2...

Page 21: ...er 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 maintenanc...

Page 22: ...ust 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 prec...

Page 23: ...01 Machine 06 About this Manual 01 17 9813 2850 3 01 17 06 About this Manual Contents Page No 01 06 06 Using the Manual 01 19...

Page 24: ...Notes 01 18 9813 2850 3 01 18...

Page 25: ...on is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the fo...

Page 26: ...t this Manual 06 Using the Manual 01 20 9813 2850 3 01 20 Make sure that the applicable fixings and threaded holes are free from contamination This includes dirt debris old sealants and compounds flui...

Page 27: ...01 Machine 09 Description 01 21 9813 2850 3 01 21 09 Description Contents Page No 01 09 12 Main Component Locations 01 23 01 09 15 Service Point Locations 01 25...

Page 28: ...Notes 01 22 9813 2850 3 01 22...

Page 29: ...Locations Introduction Figure 5 G E K M H J A C D B L F A Loader arms B Quickhitch option C ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure cab D Engine cover E Hydraulic...

Page 30: ...01 Machine 09 Description 12 Main Component Locations 01 24 9813 2850 3 01 24 J Battery K Battery isolator switch L Maintenance struts option M Transmission fill...

Page 31: ...2850 3 01 25 15 Service Point Locations Introduction Figure 6 D A C A F B E G H A Air filter assembly B Engine oil filter C Water Separator D Engine oil filler point E Hydraulic oil filler point F Eng...

Page 32: ...may also be added as an option or as a standard fit If there is no auxiliary tank fitted the filler is under the engine cover as shown If the auxiliary tank is fitted both tanks are filled from the au...

Page 33: ...chine 09 Description 15 Service Point Locations 01 27 9813 2850 3 01 27 Figure 8 A B A Filler location Standard fuel tank some machines B Filler location Auxiliary tank If fitted standard on some mach...

Page 34: ...01 Machine 33 Cleaning 01 28 9813 2850 3 01 28 33 Cleaning Contents Page No 01 33 00 General 01 29...

Page 35: ...he 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 re...

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 o...

Page 37: ...6 03 Attachments Couplings and Load Handling Contents Page No 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 30 Shovel 03...

Page 38: ...Notes 9813 2850 3 2016 10 06...

Page 39: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 2850 3 03 1 00 Attachments Contents Page No 03 00 00 General 03 3...

Page 40: ...Notes 03 2 9813 2850 3 03 2...

Page 41: ...ients 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 manufactu...

Page 42: ...r 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 Loa...

Page 43: ...03 Attachments Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9813 2850 3 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 2850 3 03 6...

Page 45: ...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 o...

Page 46: ...e 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...

Page 47: ...the attachment the Quickhitch isolator switch is used to divert the hydraulic power 1 Park the machine on solid level ground 2 Lower the lift arm until the attachment is on the ground 2 1 Servo contro...

Page 48: ...iary roller or button Push the roller until the locking pins are retracted Refer to Figure 13 5 3 Multi controls lever Push the lever until the locking pins are retracted Refer to Figure 14 6 Release...

Page 49: ...ust touches the attachment 4 Engage the park brake and put the transmission in neutral 5 Raise the lift arms and engage the pivot shaft into the hooks Stop the movement as soon as the pivot shaft is e...

Page 50: ...ngaged Refer to Figure 24 Figure 24 E E Auxiliary roller button 8 3 Multi controls levers Pull the lever until the locking pins are engaged Refer to Figure 25 Figure 25 F F Multi control lever optiona...

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