JCB 406, 407, 408, 409 Wheel Loading Shovel Service Manual – 9803/4200-11

This workshop repair service manual PDF download for the 406, 407, 408, 409 JCB Wheel Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheel Loading Shovel
406, 407, 408, 409
* 409 Telemaster

JCB 407 and 409 Machines commence from S/N: 632700.
Unless otherwise stated, information for JCB 406 also applies to JCB 407 and information for 408 also applies to JCB 409 and the JCB 409 Telemaster.

TABLE OF CONTENTS :

Section 1 – General
Section 2 – Hydraulics
Section 3 – Attachments
Section 4 – Body and Framework
Section 5 – Engine
Section 6 – Transmission
Section 7 – Axles
Section 8 – Brakes
Section 9 – Hydraulic Steering
Section 10 – Electrics
Section 11 – Service Tools

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/4200 Issue 11
Total Pages : 457

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completely searchable PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Contents

General
Fluids, Lubricants, Capacities and Specifications
406/408
407/409
409 Telemaster
Torque Settings
Service Schedules
Greasing
Shovel Pivot Pins
Loader End
Centre Pivot and Steering Ram
Intermediate Propshaft
Propshafts (except Intermediate)
Greasing (409 Telemaster)
Boom Wear Pad Runways
Boom Pivot Points

Hydraulics
Technical Data
406 and 407
408 and 409
409 Telemaster
Fluid Level and Filter
406
408
Tank and Suction Strainer
Pump
Operation
Removal, Replacement and Inspection
406
407 and 409
System Neutral Circuit
Loader Valve
Neutral Circuit
Load Hold Check Valve – OPeration 1
Load Hold Check Valve – Operation 2
Float Operation
M.R.V. Operation
A.R.V. Operation
Removal and Replacement
406
408
Dismantling and Assembly
Relief Valve Inter-Section Sealing
Standard Spools
Float (Lift) Spool
Pressure Testing – M.R.V.
Loader Valve (409 Telemaster)
Neutral Circuit
Boom Lift Operation
Boom Lower Operation
Hose Burst Operation
Boom Extend Operation
Removal and Replacement
Dismantling and Assembly
Relief Valve and Inter-section Sealing
Solenoid Operated Spool
Pilot Pressure Operated Spool
Pressure Testing
Main and Auxiliary Relief Valves
Servo
Typical Ram
Cutaway Illustration
Removal and Replacement
406
408
Metric Ram
Schematic Circuit (Cetops)
406
408
409 Telemaster

Body and Framework
Doors and Windows
406
406 Metal Framed Type
408
407 and 409
Direct Glazing
Cab Removal and Replacement
Central Pivot Dismantling and Assembly
406
408
Bearings
Quickhitch
Operation
Dismantling and Assembly
406 to serial no. 631007
406/408 from serial no. 631008
Loader Arms
Pivot Seal Fitting
406 to serial no. 631007
406/408 from serial no. 631008
Rivet Nut Fitting Procedure
Loader Arm (409 Telemaster)
Boom Shim Adjustment

Engine
Technical Data
406
408
407, 409
Oil and Filter
D3.152
1004-LR
Fuel Filter and Sediment Bowl
D3.152
1004-LR
Fuel Lift Pump
Fuel System Bleeding
D3.152
1004-LR
Cooling System
D3.152
1004-LR
Fan Belt
Air Filter
Farr Rotopamic Air Filter (Option)
Engine Removal and Replacement

Transmission
Technical Data
Syncro Shuttle
Powershift
Towing Procedure
Oil System
Syncro Shuttle
Powershift
Transfer Gearbox
Description
Transmission
Syncromesh
Syncro Shuttle
Fault Finding
Syncro Shuttle
Syncro Shuttle
Dismantling
Assembly
Torque Converter
Stall Test
Removal and Replacement
Oil Cooler Relief Valve
To Machine 630373
Driveshafts
406
408
Driveshaft Phasing
Transfer Gearbox
Cutaway Illustrations
Removal and Replacement
to machine 632699
from machine 632700
Dismantling and Assembly
to machine 632699
from machine 632700
Powershift Transmission
General Description
Hydraulic Operation
Drivepaths
Fault Finding
Dismantling
Assembly
Input Clutch
Dismantling
Assembly
Reverse Clutch
Dismantling
Assembly
Mainshaft
Dismantling
Assembly
Layshaft
Dismantling
Assembly
Solenoid Identification
Torque Converter Stall Test
Clutch Leakage Test
Pressure and Flow Testing
A.C.U. Testing
A.C.U. Fault Finding
PTFE Oiston Ring Seals – Fitting Procedure
End Float Checking Procedure

Axles
Technical Data
406
408
Removal and Replacement – 406 with Hurth Axles
Hurth Axle
Cutaway Illustration
Dismantling
Assembly
Crownwheel and Pinion Meshing
JCB Axle
Oil Level
Removal and Replacement
Cutaway Illustration
406
408
Drivehead (without LSD) – Dismantling
Differential (without LSD) – Dismantling
Differential (without LSD) – Assembly
Drivehead (without LSD) – Assembly
Crownwheel and Pinion Meshing
Renewing the Pinion Oil Seal
Drivehead (with LSD) – Dismantling
Differential (with LSD) – Dismantlig
Differential (with LSD) – Assembly
Dirvehead (with LSD) – Assembly
Hubs, Driveshafts and Breaks
Dismantling
Assembly

Brakes
Technical Data
Brake Circuit Schematic
Brake Circuit Description
Parking Brake
Machines up to 631475
Machines from 631476
Testing
Hurth Axle (406)
Bleeding Procedure
Service Brake Adjustment
Master Cylinder
Removal and Replacement
Dismantling and Assembly
JCB Axle (406/408)
Bleeding Procedure
Master Cylinder
Removal and Replacement
Dismantling and Assembly
JCB Axle (407/409)
Bleeding Procedure
Foot Brake Valve
Accumulator Charge VAlve
Removal and Replacement
Dismantling and Assembly
Pressure Testing

Hydraulic Steering
Technical Data
Priority Valve
Operation 1 – Neutral
Operation 2 – Turning
Steering
Operation 1 – Neutral
Operation 2 – Right Turn
Operation 3 – Left Turn
Operation 4 – Left Turn, Unassisted
Operation 5 – Shock Valve
Priority Valve
Machines with Hurth Axles
Machines with JCB Axles
Steering Unit – Removal and Replacement
Machines wtih Hurth Axles
Machines with JCB Axles
Steering Column – Dismantling and Assembly
Machines with Hurth Axles
Machines with JCB Axles
Steering Unit – Dismantling and Assembly
Steering Ram
406 machines to serial no. 631796
408 machines to serial no. 631870
406 machines from serial no. 631797
408 machines from serial no. 631871
407 and 409 machines
Steering Circuit Schematic (409 Telemaster)

Electrics
Technical Data
406 to ser. no. 630685
408 to ser. no. 630685
406/408 from ser. no. 630686
406/408 from ser. no. 632375
407/409 from ser. no. 632700
407/409/409 Telemaster from ser. no. 633676
Batteries
Testing Specific Gravity
Battery Testing
Alternator
General Description
Service Precautions
Charging Circuit Check
Charging Test
Removal and Replacement
Starter Motor
Starting Circuit Test
Removal and Replacement
Lucas 2M113
Lucas M127
Schematic Circuits
406 to ser. no. 630685
408 to ser. no. 630685
406/408
Syncro Shuttle from ser. no. 630686
Powershift from ser. no. 630686
407/409
Syncro Shuttle from ser. no. 632700
Powershift from ser. no. 632700
407/409/409 Telemaster from ser. no. 633767
409 Telemaster
Wiring Lists 406/408 from ser. no. 630686 to 632699
Syncro Shuttle
Panel Harness
Main Harness
Powershift
Panel Harness
Main Harness
Wiring Lists 407/409 from ser. no. 632700
Syncro Shuttle
Panel Harness
Main Harness
Powershift
Panel Harness
Main Harness
Cab and Engine Cover Harness
Wiring Lists 409 Telemaster
Auxiliary Harness
Cab Roof Harness
Wiring Lists 407/409 from Ser. No. 633051
Syncro Shuttle Main Harness
Powershift Main Harness
Wiring Lists 409 Telemaster
Auxiliary Harness
Cab Roof Harness
Wiring Lists 407/409/409 Telemaster from ser. no. 633676
Powershift
Main Harness
Panel Harness
Syncro Shuttle
Main Harness
Panel Harness
A.C.U.
Panel Harness
Safe Load Indicator
Adjustment
Transducer Removal and Replacement
Testing

Service Tools
Service Tools Numerical List
Tools
Section 2 – Hydraulics
Section 4 – Body and Framework
Section 5 – Engine
Section 6 – Transmission
Section 7 – Axles
Section 9 – Hydraulic Steering
Section 10 – Electrics
Sealing and Retaining Compounds

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