JCB 406, 409 Wheeled Loading Shovel Service Manual – 9803/4310-03

(S/N: 1163000 Onwards)
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This workshop repair service manual PDF download for the 406, 409 JCB Wheeled 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 Wheeled Loading Shovel 406 – from S/N: 1163000 Onwards
JCB Wheeled Loading Shovel 409 – from S/N: 1163000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/4310-03
Total Pages : 491

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 completly searcheble 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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9803-4310

Section 1 – General Information
General Information
Identifying your Machine
Torque Settings
Service Tools
Service Consumables
Introduction
Schematic Codes
Colour Codes
Black and White Codes
Identifying your Machine
Unit Identification
Identification Plate
Explanation of Vehicle identification Number (VIN)
Unit Identification
Typical Engine Identification Number
Serial Plates
Typical Axle Plate
Typical Transmission Plate
Typical Chassis Plate
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
Numerical List Section F – Transmission
Tool Detail Reference Section F – Transmission
Numerical List Section H – Steering
Tool Detail Reference Section H – Steering
Numerical List Section K – Engine
Tool Detail Reference Section K – Engine
Service Consumables
Sealing and Retaining Compounds

Section 2 – Care and Safety
Care and Safety
Safety
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety decals

Section 3 – Routine Maintenance
Routine Maintenance
Routine Maintenance
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Introduction
Periodic Replacement of Safety Related Components
Lubricants and Capacities
Seat Belt
Checking the Seat Belt Condition and Security
Articulation lock
Installing the Articulation lock
Removing the Articulation Lock
Loader Arm Support Strut
Installing the Support Strut
Removing the Support Strut
Engine Compartment
Opening and Closing the Engine Cover
Greasing
Loader Arms
Articulation Joint
Propshaft Joints
Steering Joints
Brakes
Inherent Characteristics
Checking the Brake Fluid Level
Testing the Parking Brake
Electrical System
Battery
Jump Starting The Engine
Fuses
Primary Fuses
Relay Identification
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Filtration
Changing the Engine Air Filter Elements (406 Machines)
Changing the Engine Air Filter Elements (409 Machines)
Heating and Ventilation
Cleaning the Cab Heater Filter
Engine Cooling
Cleaning the Engine Cooling System
Alternator Drive Belt
Adjusting the Drive Belt
Fuel System
Types of Fuel
Filling the Tank
Changing the Fuel Filter
Draining the Sedimenter Bowl
Cleaning the Sedimenter Bowl
Hydraulic System
Checking the Fluid Level
Changing the Filter Element
Refilling the Hydraulic System
Replacing the `Tank’ Suction Strainer Filter
Replacing the Filter-head Suction Strainer Filter
Wheels and Tyres
Tyre Sizes and Pressures
Tyre Inflation
Checking the Wheel Nut Torques
Transmission Drop-box
Checking the Oil Level
Draining and Refilling the Drop-box Oil
Front and Rear Axles
Checking the Front Differential Oil Level
Draining and Refilling the Front Differential Oil
Checking the Rear Differential Oil Level
Draining and Refilling the Rear Differential Oil
Checking the Hub Oil Level
Draining and Refilling the Hub Oil
Windscreen Washer
Filling the Reservoir

Section A – Attachments
Attachments
Optional Attachments
Quick Release Couplings
Connecting and Disconnecting

Section B – Body and Framework
Body and Framework
Service Tools
Slide Hammer Kit
Fitting Procedure
Rivet Nuts
Fitting Procedure
Service Procedures
Cab Structure
Direct Glazing
ROPS/FOPS Structure
Cab
Removal and Replacement
Preparation
Removal
Replacement
Engine Cover
Removal and Replacement
Removal
Replacement
Articulated Joint
Removal And Replacement
Prepare The Machine
Separating The Machine Halves
Inspecting the Articulating Joint
Renewing the Bushes
Reconnect the Machine Halves
Quickhitch
Dismantling and Assembly
When Dismantling
When Assembling
Loader Arms
Removal and Replacement
Removal
Replacement
Pivot Seal Fitting

Section C – Electrics
Electrics
Technical Data
General data
Fuses and Relays
Fuses and Relays
Service Procedures
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Starter Motor
Starting Circuit Test
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Schematic Circuits
406 Machines up to serial no. 1299999
Primary Fuses, Ignition Switch, Ignition Relays and Starter Motor
Instrumentation
Immobiliser, Interior Light, Radio and SRS
Front Wipe, Rear Wipe, Heater/AC and Face Fan
Front and Rear Worklights and Beacon
Roadlights
F/N/R, High Speed and Creep Speed
Servo Cut-off, Quickhitch, Horn and Suspension Seat
Earth Points, Cab and Cab Roof
Earth Points, Front and Rear Chassis
Machines from serial no. 1300000 (406), 1302000 (409)
Fuses, Ignition Switch, Ignition Relays and Starter Motor
Instrumentation
ESOS, Interior Light, Radio and SRS
Front Wipe, Rear Wipe, Heater/AC and Face Fan
Front and Rear Worklights and Beacon
Roadlights
F/N/R, High Speed and Creep Speed
Servo Cut-off, Quickhitch, Horn and Suspension Seat
Earth Points
Harness Data
Drawings and Interconnection
Harnesses
Drawings
Alternator
Removal, Inspection and Replacement
General
Removal
Inspection
Replacement
Starter Motor
Removal and Replacement
Preparation
Removal
Replacement

Section D – Controls
Controls
Control Rods and Linkages
Dismantle and Assemble
Loader Valve Controls

Section E – Hydraulics
Hydraulics
Technical Data
General Data
Service Tools
Numerical List
Functional Descriptions
Main Hydraulic Pumps
Transmission Pump
Components of Transmission Pump
Associated Components
Ports
Operation
Axial Piston Pump
Charge Pump
Displacement Angle (DA) Control Valve
Directional Control Valve (DCA)
Swash Control Piston
High Pressure Relief and Control Pressure Make-up Valve (HPRV)
Pressure Cut off Valve (PCV)
Control Pressure Relief Valve (CPRV)
Inching Valve
Transmission Motor
Components of Transmission Pump
Ports
Check Valves
Swivel Angle Control
Flushing and Boost Pressure Valve
Loader Valve
Description
Main Service Spools
Relief Valves
Circuit Descriptions
Loader Valve – Neutral Circuit
Load Hold Check Valves
Arms Lower
Auxiliary Relief Valve (ARV) Operation
Basic Systems Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
406 Machines
409 Machines (3 Spool)
409 Machines (4 Spool)
Service Procedures
Connecting and Disconnecting Hydraulic Hoses
Venting Hydraulic Pressure
Connecting the Hoses
Disconnecting the Hoses
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Relief Valve Testing
Main Relief Valves (M.R.V.)
Auxiliary Relief Valves (A.R.V.)
Main Pump Testing
Pumps (406 Machines)
Removal and Replacement
Preparation
Hydraulic Service and Fan Pumps
Transmission, Service and Fan Pump Set
Dismantling and Assembly
Hydraulic Service and Fan Pumps
Coupling
Engine to Transmission Pump
Pumps (409 Machines)
Removal and Replacement
Preparation
Hydraulic Service and Fan Pumps
Transmission, Service and Fan Pump Set
Dismantling and Assembly
Hydraulic Service and Fan Pumps
Coupling
Engine to Transmission Pump
Hydraulic Motors
Transmission Motor
Removal and Replacement
Engine Cooling Fan Motor
Removal and Replacement
Dismantling and Assembly (406 Machines)
Dismantling and Assembly (409 Machines)
Control Valve
Removal and Replacement
Preparation
Dismantling and Assembly
Preparation
Dismantling
Inspection
Assembly
Transmission Set-Up
Start-Up Procedure
Initial Preparation
Start-Up
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Loader Shovel Ram
Dismantling and Assembly
Typical Ram
JCB Ram Sealing Procedure
Fault Finding
Main Hydraulic Services
Main Tandem Hydraulic Pump
Transmission Hydraulics
Basic System Fault Finding
Hydrostatic Transmission
Pump and Motor Test Points
Loader Valve
Basic System Fault Finding

Section F – Transmission
Transmission
Technical Data
406
Tyre Sizes and Pressures
Front Axle
Rear Axle
Transfer Gearbox
Service Tools
Numerical List
Towing Procedure
Towing a Machine
Prepare the Transmission Pump for Towing
Preparation for Towing
Axles
Removal and Replacement
Front Axle
Rear Axle
Hubs and Driveshaft
Dismantling and Assembly
Preparation
Transmission Drop-box
Dismantling and Assembly
Preparation
Front Axle Drive Head
Differential Assembly (Standard)
Preparation
Differential Assembly (LSD)
Preparation
Pinion Assembly
Preparation
Crown Wheel and Pinion
Set-up Procedure
Rear Axle Drive Head
Differential Assembly
Preparation
Pinion Assembly
Preparation
Crown Wheel and Pinion
Set-up Procedure
Propshafts
Removing and Replacing
Removing
Replacing

Section G – Brakes
Brakes
Technical Data
Service and Parking Brake
Service Procedures
Bleeding the Brake System
Adjusting the Park Brake Cable
Preparation
Adjusting the Cable
Service and Mechanical Park Brake
Dismantling and Assembly
Preparation
Dismantling
Assembly

Section H – Steering
Steering
Technical Data
System Type
Steering Unit
Priority Valve
Rams
Service Tools
Numerical List
Basic Operation
Hydraulic Circuit Operation
Priority Valve
Neutral Operation
Turning Operation
Steering Unit
Neutral Operation
Steering Operation – Right Turn
Steering Operation – Left Turn
Left Turn – Unassisted
Shock Valve Operation
Service Procedures
Pressure Testing
Steering Relief Valve
Standby Pressure Testing
Priority Valve
Cleaning
Priority Valve
Removal and Replacement
Dismantling and Assembly
Dismantling
Assembly
Bleeding
Hydraulic Steering Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Relief Valve Cartridge
Shock Valves
Fault Finding
Introduction – 406
Fault Tables
Mechanical and Hydraulic – 406

Section K – Engine
Engine
Technical Data
4 Cylinder Air Cooled Diesel (406 Machines)
4 Cylinder Turbocharged Diesel (409 Machines)
Fault Finding
Basic Engine Fault Diagnostics

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