- This 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.
JCB 407 and 409 Machines commence from Serial Number 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.
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 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 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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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