JCB 406 409 Wheeled Loading Shovel Service Manual 9803/4310-05

Description

File Details

• Manual type: Service Manual (workshop repair and overhaul)
• Brand / models: JCB wheeled loading shovel 406 and 409
• Language: English
• Page count: 590
• File format: PDF
• Publication No.: 9803/4310-05 (section pages also carry 9803/4310-01, -03 and -04 footers)

The JCB 406 409 Wheeled Loading Shovel Service Manual 9803/4310-05 is written for JCB Distributor Service Engineers who already understand workshop practice on hydraulic earthmoving equipment. It is compiled in numbered front sections plus lettered overhaul sections so new items can be inserted without renumbering the whole book. Left-hand and right-hand are viewed from the rear of the machine facing forwards. Torque figures given as a single value may be varied by plus or minus 3 percent; dry-thread figures may be reduced by one third when threads are lubricated.

Machine identification and serial notes

An identification plate on the left-hand loader-arm pillar carries the machine and major-unit serial numbers. The Vehicle Identification Number is explained in the form SLP 406 A L T E 1163000 (world manufacturer SLP = JCB, model 406, build A = articulated, type L = loader, year code, location E = England, then the machine serial). Separate plates cover the engine (stamped on the valve cover), Dana Spicer axles, Rexroth transmission and the chassis CE plate. Engine type codes on the engine plate include AA (4-cylinder naturally aspirated) and AB (4-cylinder turbo).

Several procedures call out serial breakpoints rather than calendar years. Twin main and fan pumps on 406 machines from serial 1163000 to 1163006 use individual suction hoses; from 1163007 a single suction line feeds both pumps. Electrical schematic sets are split between machines to 1299999 and machines from 1300000 (406) / 1302000 (409), including a separate 409 high-speed transmission circuit.

Chapters Covered

• Section 1 – General Information: introduction; schematic colour and black-and-white codes; unit identification and VIN; typical engine, axle, transmission and chassis plates; zinc / Dacromet torque tables (UNF Grade S, metric 8.8 / 10.9 / 12.9, rivet nuts, cap screws); hydraulic O-ring face-seal, BSP, SAE and Torque-Stop hose settings; numerical service-tool lists for Sections B, C, E, F, H and K; sealing and retaining compounds
• Section 2 – Care and Safety: workshop warnings and cautions used throughout later procedures
• Section 3 – Routine Maintenance: service requirements; health and safety for lubricants and batteries; fluids, lubricants and capacities; making the machine safe with the loader arm raised; cleaning; ROPS/FOPS checks (mounting bolts 135 Nm / 99.5 lbf ft); greasing of loader arms (11 points on 406, 13 on 409), articulation, steering, driveshafts and quickhitch; optional automatic greasing system; park and service brakes; battery, jump starting, fuses and relays; engine oil, filter, drive belt and air filter; fuel filter, sedimenter bowl, strainer and priming; hydraulic pressure release and filters; transmission drop-box and axles; tyre inflation and wheel-nut torques; windscreen washers; fire extinguisher
• Section A – Attachments: optional attachments; flat-face quick-release couplings (connecting and disconnecting, do’s and don’ts)
• Section B – Body and Framework: slide-hammer and rivet-nut tools; cab structure, direct glazing, ROPS/FOPS; cab removal and replacement; engine cover; articulated joint (separating halves, inspecting, renewing bushes); quickhitch dismantling and assembly; loader-arm removal, replacement and pivot-seal fitting
• Section C – Electrics: 12 V negative-earth data; battery JCB 729/10663 Type 663 wet 12 V 115 Ah; 12 V 80 A alternator; fuses and relays; battery tests and specific gravity; multimeter use; wire and harness numbering; harness repair; starter circuit test; alternator charging tests; schematic circuits for machines to 1299999 and from 1300000 / 1302000 (instrumentation, wipers, heater/AC, worklights, roadlights, F/N/R, high and creep speed, servo cut-off, quickhitch, horn, suspension seat, earth points, ESOS, immobiliser); harness drawings; alternator and starter motor R&I (rotor-to-blower-jacket clearance 0.2–0.8 mm)
• Section D – Controls: control rods and linkages; loader-valve controls dismantle, assemble and locking-pin adjustment
• Section E – Hydraulics: pump, motor and valve data; functional descriptions of the transmission pump, charge pump, DA control, HPRV, PCV, CPRV, inching valve, transmission motor, loader control-valve and ARVs; schematic circuits for 406, 409 3-spool, 409 4-spool and 409 4-spool 40 kph; hose connect/disconnect and contamination control; MRV and ARV testing; main-pump testing; 406 and 409 pump R&I and overhaul; transmission and fan-motor work; control-valve overhaul; hydrostatic system description and start-up (including 40 kph Bosch ECU gear-change); ram precautions, loader-shovel ram R&I, typical ram overhaul and JCB ram sealing; fault finding for main services, tandem pump, transmission hydraulics and loader valve
• Section F – Transmission: 406 tyre sizes and pressures; Dana Spicer front axle (overall ratio 1:19.33, crownwheel and pinion 9:29, hub reduction 6:1); rear axle Dana Spicer 315/111/73; transfer gearbox; towing procedure; axle R&I; hubs and driveshafts; drop-box single-speed and two-speed options with gear-switch and speed-sensor setup; front and rear drive-head differentials (standard and LSD), pinion assemblies, crown-wheel and pinion set-up; driveshaft R&I
• Section G – Brakes: oil-immersed multiplate service brake (hydraulic, rear-axle casing, 6 friction plates / 6 steel discs, pack max 43.5 mm) and cable-operated parking brake; bleeding; park-brake cable adjustment; service and mechanical park-brake dismantle and assemble
• Section H – Steering: full-power hydrostatic steering via priority valve and 200 OSPC unit (200 cc/rev; relief 170 +/- 3 bar at 1500 rev/min; shock valve 225 bar); ram data; circuit operation (neutral, left, right, unassisted, shock valve); pressure and standby testing; priority-valve clean, R&I and bleed; steering-unit R&I, cartridge and shock-valve service; 406 fault tables
• Section K – Engine: technical data for 4-cylinder air-cooled diesel on 406 machines (F4L 2011, 94 x 112 mm, 3108 cm3, 19:1, NA direct injection) and 4-cylinder turbocharged diesel on 409 machines (TD 2011 L, 332/R8670, 75 hp at 2600 rpm, 96 x 125 mm, 3620 cm3, 18:1); oil pressures and change quantities; valve clearances (406: inlet 0.3 +/- 0.1 mm, exhaust 0.5 +/- 0.1 mm); injector opening 210 +8 bar; firing order 1-3-4-2; basic engine fault diagnostics

IMAGES PREVIEW

Taken together, the JCB 406 409 Wheeled Loading Shovel Service Manual 9803/4310-05 gives a trained technician the data, circuit descriptions and step sequences needed to service both the compact 406 air-cooled machine and the turbocharged 409, including the optional 40 kph road-speed hydrostatic package. Colour and monochrome schematic codes at the front of the book are used on the hydraulic drawings so pressure, servo, exhaust, cavitation and lock-up conditions can be read consistently.

Hydraulic and hydrostatic working values

Section E lists a 40 cc/rev transmission main pump with charge pressure 25–28 bar at 2760 rpm flight speed, 8 cc/rev charge pump and 420 bar high-pressure settings at ports A and B. The main hydraulic pump is a 20 cc/rev fixed-displacement unit flowing 63 l/min at 2200 rev/min no-load and 58 l/min at 2150 rev/min full load, with 230 bar continuous pressure. The fan pump is 8 cc/rev (22 l/min at zero pressure / 20 l/min at system pressure at 2000 rev/min); fan motor maximum speed is 2500 rpm at 60 °C oil temperature on the 14 in fan. The transmission motor is a bent-axis variable piston unit at 80 cc with the same 420 bar port settings.

The sectional loader valve is rated 60 l/min. Relief settings include main MRV 230 bar, crowd ram head 150 bar, crowd ram rod 240 bar, lift ram 300 bar, steering relief 170 bar and steering shock 225 bar. Filter by-pass is 2 bar. Crowd ram 100/50 mm bore/rod, 436 mm stroke; lift ram 100/60 mm, 611 mm stroke; steer ram 70/30 mm, 274 mm stroke. Later hydrostatic pages for the Rexroth closed-loop DA/HA package quote a 11.6 cc/rev charge pump, 0–56 cc/rev drive pump, 22–107 or 0–107 cc/rev motors, 450 bar pressure cut-off plus charge, charge 25 bar at idle / 28 bar at maximum rpm, DA start of control 50 bar at 1150 rpm, and inching 3–10 bar in the brake line. 40 kph machines add a Bosch ECU, tortoise / hare / gear-2 icons and a propshaft speed sensor (tortoise 6 kph = 546 Hz, hare 20 kph = 1365 Hz, roading 40 kph = 2730 Hz).

Electrical, brake, axle and engine data

The electrical system is 12 V negative earth with the 115 Ah wet battery and 80 A alternator quoted above. Wiring diagrams cover primary fuses, ignition, starter, instrumentation, wipers, heater or air-conditioning, worklights, roadlights, forward/neutral/reverse, high and creep speed, servo cut-off, quickhitch, horn, suspension seat, earth points, ESOS, immobiliser and the 409 high-speed transmission set. Harness drawings and connector data sit after the schematics so a technician can trace a circuit from symbol to pin.

Service and park brakes share the rear-axle casing as oil-immersed multiplate packs. Bleeding uses two bleed points and the fluid specified in Section 3. Park-brake work is cable adjustment plus full piston and pack overhaul. Front axle data for the 406 includes Dana Spicer designations 111/92 LSD (190 kg) and 11/110 standard (189 kg), 29-tooth crownwheel and 9-tooth pinion. Rear axle 315/111/73 weighs 258 kg without wheels; both axles use 6:1 hub reduction. Tyre tables list 18 in and 20 in rim options such as 12.5/80-18 at 3.0 bar front / 2.5 bar rear and 405/70 R18 at 2.5 / 2.25 bar.

Engine pages keep workshop limits in one place: 406 F4L 2011 oil change about 10 litres (10.5 litres with filter), minimum oil pressure 1.4 bar at 900 rpm, 2.2 bar at 1800 rpm and 3.0 bar at 2800 rpm; 409 TD 2011 L uses the same oil quantities with pressure points at 900 / 1600 / 2600 rpm and is listed as 75 hp at 2600 rpm.

Use this manual to service the machine correctly

With the JCB 406 409 Wheeled Loading Shovel Service Manual 9803/4310-05 a workshop can schedule routine work from Section 3, then move into overhaul of the cab and articulation, wiring and charging, loader-valve linkages, hydrostatic pump and motor, Dana Spicer axles and drop-box, multiplate brakes, priority-valve steering and the Deutz-pattern 2011 engines. Correct pressures, ram dimensions, torque tables and bleed sequences reduce the chance of damaged pumps, leaking rams or a parking brake that will not hold. After payment you receive an instant PDF download — no shipping — that you can open on any device and print the pages you need at the bench.