Part of the JCB Repair Manuals.
Tracking down a reliable JCB 409 service manual pdf doesn't have to be a headache. This 457-page factory reference (OEM #9803/4200) breaks down every teardown and rebuild procedure for the JCB 406, 407, 408, 409, and 409 Telemaster wheel loaders and telehandlers. Open it up to find complete hydraulic schematics covering the loader valve, steering ram, and main relief circuits. You also get full electrical wiring diagrams, syncro shuttle transmission fault-finding charts, and detailed axle disassembly instructions. Lock down the 1/2-inch UNF Grade S hardware to 117 Nm and verify the M12 fasteners sit at 98 Nm before sending the loader back to the dirt. Stop wasting hours hunting for the right fluid capacities. Download this searchable, bookmarked file directly to your tablet and start turning wrenches.
Complete the set for your 406–409
- 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 | 2-17 | Fluids, Lubricants, Capacities & Specifications, Service Schedules, Greasing |
| Hydraulics | 18-73 | Technical Data (and 407, And 409, Telemaster), Fluid Level and Filter (406, 408), Tank and Suction Strainer, Pump (Operation, Removal, Replacement and Inspection, 406, And 409) |
| Attachments | 74-108 | Doors and Windows, Direct Glazing, Central Pivot Dismantling and Assembly, Quick Hitch - Dismantling and Assembly, Loader Arms - Pivot Seal Fitting, Boom Shim Adjustment |
| Engine | 109-128 | Technical Data, Engine Removal and Replacement |
| Transmission | 129-261 | Technical Data, Syncro Shuttle Transmission - Fault Finding, Syncro Shuttle - Dismantling, Syncro Shuttle - Assembly, Driveshafts, Transfer Gearbox, Powershift Transmission |
| Axles | 262-301 | Axles - Dismantling, Axles - Assembly, Drive Head - 406 Machines with Jcb Axles Without Limited Slip Differential |
| Brakes | 302-324 | Accumulator Charge Valve (407/409 Machines) |
| Hydraulic Steering | 325-355 | Hydraulic Steering Unit |
| Electrics | 356-443 | Technical Data, Alternator, Syncro Shuttle Wiring List - Panel Harness, Syncro Shuttle Wiring List - Main Harness, Powershift Wiring List - Panel Harness |
| Service Tools | 444-457 | Body & Framework |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Service Interval Reset | Not found. The manual lists service schedules but does not describe a procedure for resetting service intervals. | p. 9 |
| Hydraulic Fault Reset | Not found. The manual provides fault finding procedures for hydraulic systems but does not describe a procedure for resetting hydraulic faults. | p. 18 |
| General UNF Grade 'S' Bolts Torque Settings (1/2 inch) | 117 Nm (12.0 kgf m, 87 lbf ft) | p. 8 |
| General Metric Grade 8.8 Bolts Torque Settings (M12) | 98 Nm (10 kgf m, 72 lbf ft) | p. 8 |
| Wiring for Chaffing Check | Check ❑ | p. 10 |
| Battery Terminals for Condition and Tightness Check | Check ❑ | p. 10 |
| Speed Transducer Position/Connections Remedy | Reposition speed transducer (nominal 2 to 3 mm gap) | p. 259 |
| Safe Load Indicator Transducer Bolt Torque (Item B) | 70 Nm (7.1 kgf m, 51.6 lbf ft) | p. 440 |
| Loader Control Valve Inter-section Sealing Rings (Item 1) Torque | 27±1.32 Nm (2.75±0.13 kgf m, 20±1 lbf ft) | p. 43 |
| 409 Telemaster | ||
| Wheel Nut Torque | Not found. The service schedule lists 'Wheel Nut Torque' as a check item, but no specific value is provided for 409 Telemaster wheel nuts. | p. 10 |
| 406, 407 | ||
| Ram Piston Head Torque (406 Machine) | 405 Nm (41.3 kgf m, 300 lbf ft) | p. 20 |
| 406 | ||
| Engine Oil Capacity (406) | 7.2 litres (1.6 UK gal) | p. 5 |
