Part of the JCB Repair Manuals.
Looking for the factory repair procedures for your wheeled loading shovel? This 590-page JCB 406 service manual pdf (OEM #9803/4310-05) breaks down every transmission drop-box, articulated joint, and hydraulic steering unit for the 406 and 409 models. You get detailed wiring diagrams mapping the entire electrical system and full hydraulic schematics covering the steering priority valves and loader controls. Open up the fault-finding sections to chase down basic engine issues, then reference the extensive torque tables before reassembling the axles. When installing the front axle driveshaft to the coupling flange, tighten the bolts to 41 Nm and secure the hydraulic system filter cap to 40 Nm. Don't waste another hour guessing at clearances and pressures. Download this file directly to your tablet, jump to the exact schematic, and get your loader back in the dirt.
Complete the set for your JCB 406 & 409 Wheeled Loading Shovel
- Operator Manual: JCB 406, 407, 409 Wheeled Loader Operator Manual
- Operator Manual: JCB 406, 409 Wheeled Loader Operator Manual
- Operator Manual: JCB 406, 408 Wheeled Loader Operator Manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-40 | Schematic Codes, Machine Identification, Torque Settings, Service Tools, Service Consumables |
| Care and Safety | 41-51 | Safety Check List, General Safety, Operating Safety, Maintenance Safety, Safety Decals |
| Routine Maintenance | 52-127 | Service Requirements, Service Schedules, Fluids/Lubricants/Capacities, Prepare Machine for Maintenance, Greasing, Electrical System |
| Section a - Attachments | 128-132 | Quick Release Couplings, Connecting Couplings, Disconnecting Couplings, Safety Warnings |
| Section B - Body and Framework | 133-163 | Service Tools, Direct Glazing, Cab Removal/Replacement, Engine Cover Removal/Replacement, Articulated Joint, Quickhitch |
| Section C - Electrics | 164-273 | Technical Data, Fuses and Relays, Battery Maintenance/Testing, Wiring Harness Repair, Starter Motor, Alternator |
| Section D - Controls | 274-280 | Control Rods and Linkages, Loader Valve Controls, Dismantle and Assemble, Adjustment |
| Section E - Hydraulics | 281-414 | Technical Data, Service Tools, Functional Descriptions, Schematic Circuits, Connect/Disconnect Hoses, Relief-Valve Testing |
| Section F - Transmission | 415-526 | Technical Data, Service Tools, Towing Procedure, Axles Removal/Installation, Hubs and Driveshaft, Transmission Drop-Box |
| Section G - Brakes | 527-546 | Technical Data, Bleeding Brake System, Adjusting Park Brake Cable, Dismantling/Assembly Park Brake, Shim Calculation |
| Section H - Steering | 547-580 | Technical Data, Basic Operation, Pressure Testing, Priority-Valve Removal/Installation, Hydraulic Steering Unit, Fault Finding |
| Section K - Engine | 581-590 | Technical Data (406), Technical Data (409), Basic Engine Fault Diagnostics |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Front Axle Driveshaft to Coupling Flange Bolt Torque | 41 Nm (4.18 Kgf m, 30.24 lbf ft) | p. 425 |
| Front Axle U-bolt Nut Torque | 600 Nm (61.2 Kgf m, 443 lbf ft) | p. 425 |
| Hydraulic System Filter Cap Torque | 40 Nm (29.5 lbf ft) | p. 117 |
| Engine Air Filter Inner Element Replacement | Every other time outer element is changed | p. 108 |
| Fuel Filter Tightening | Tighten the bowl a further quarter of a turn (after hand-tight) | p. 111 |
| BSP Hose to Adaptor Torque (example for 1/8 in. BSP) | 14.0 - 16.00 Nm (1.4 - 1.6 kgf m, 10.3 - 11.8 lbf ft) | p. 18 |
| Battery Type and Capacity | JCB 729/10663 Type 663 Wet 12 Volts 115 Amp/hour | p. 168 |
| Alternator Nuts to Blower-Housing Torque | 4 Nm (35.4 lbf-in) | p. 268 |
| Rotor to Blower Inlet-Jacket Clearance (Alternator) | Minimum 0.2 mm (0.0078 in.), Maximum 0.8 mm (0.031 in.) | p. 270 |
| Drive Belt Tension (Deflection) | 15 mm (5/8 in.) | p. 105 |
| Drive Belt Tension (Force) | Approximately 210N | p. 105 |
| O-rings, Seals and Gaskets Replacement | Renew whenever disturbed unless otherwise instructed | p. 49 |
