JCB 406, 407, 408, 409, 409 Telemaster Wheel Loader Service Manual

Name: JCB 406, 407, 408, 409, 409 Telemaster Wheel Loader Service Manual
Brand: MidWestTech
SKU: 9803-4200
Price: 69.75 USD
Availability: InStock

457 pages · Publication 9803-4200

$69.75

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Models: 406, 407, 408, 409, 409 Telemaster
Serial coverage: 406 630000 SN and up, 407 632700 SN and up, 408 630000 SN and up, 409 632700 SN and up
Manual type: Service Manual
Pages: 457
Publication: 9803-4200
Condition: Brand new

JCB 406, 407, 408, 409, 409 Telemaster Wheel Loader Service Manual, publication 9803-4200

What's inside

From the manual's own table of contents: 10 sections, 174 entries. See sample pages (PDF, 341 KB)

Search the contents

General10 topics

Telemaster
- Torque Settings
Service Schedules
- Shovel Pivot Pins
- Loader End
- Central Pivot and Steering Ram
- Intermediate Propshaft
- Propshafts (except Intermediate)
- Boom Wear Pad Runways
- Boom Pivot Pins

Hydraulics29 topics

Telemaster
Tank and Suction Strainer
- Operation
System Neutral Circuit
System Neutral Circuit (409 Telemaster)
- Neutral Circuit
- Load Hold Check Valve - Op 1
- Load Hold Check Valve - Op 2
- Float Operation
- M.R.V. Operation
- A.R.V. Operation
- Relief Valve/inter-section Sealing
- Standard Spools
- Float (Lift) Spool
- Main Relief Valve
- Neutral Circuit
- Boom Lift Operation
- Boom Lower Operation
- Hose Burst Operation
- Boom Extend Operation
- Removal and Replacement
- Relief Valve Inter-section Sealing
- Solenoid Operated Spool
- Pilot Pressure Operated Spool
- Main and Auxiliary Relief Valves
- Servo
- Cutaway Illustration
- Metric Ram
- Telemaster

Body & Framework7 topics

Metal Framed Type
Direct Glazing
Cab Removal and Replacement
- Bearings
- Operation
Rivet Nut Fitting Procedure
- Boom Shim Adjustment

Engine5 topics

Fuel Lift Pump
Fan Belt
Air Filter
Farr rotopamic Air Filter (Option)
Engine Removal and Replacement

Transmission22 topics

Syncro Shuttle
Towing Procedure
- Syncro Shuttle
- Powershift
- Transfer Gearbox
- Transmission
- Synchromesh
- Syncro Shuttle
- Dismantling
- Assembly
- Stall Test
- Removal and Replacement
- Driveshaft Phasing
- from machine 632700
- General Description
- Hydraulic Operation
- Drivepaths
- Fault Finding
- Dismantling
- Assembly
- Dismantling
- Assembly

Axles21 topics

with Hurth Axles
- Cutaway Illustration
- Dismantling
- Assembly
- Crownwheel and Pinion Meshing
- Oil Level
- Removal and Replacement
- Cutaway Illustration (406)
- Cutaway Illustration (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) - Dismantling
- DIfferential (witht LSD) - Assembly
- Drivehead (with LSD) - Assembly
- Dismantling
- Assembly

Brakes18 topics

Technical Data
Brake Circuit Schematic
Brake Circuit Description
- Machines up to 631475
- Machines from 631476
- Testing
- Bleeding Procedure
- Service Brake Adjustment
- Removal and Replacement
- Dismantling and Assembly
- Bleeding Procedure
- Removal and Replacement
- Dismantling and Assembly
- Bleeding Procedure
- Foot Brake Valve
- Removal and Replacement
- Dismantling and Assembly
- Pressure Testing

Hydraulic Steering20 topics

Operation 1 - Neutral
- Operation 2 - Turning
- Operation 1 - Neutral
- Operation 2 - Right Turn
- Operation 3 - Left Turn
- Operation 4 - Left Turn, Unassisted
- Operation 5 - Shock Valve
- Machines with Hurth Axles
- Machines with JCB Axles
- Machines with Hurth Axles
- Machines with JCB Axles
- Machines with Hurth Axles
- Machines with JCB Axles
- Dismantling and Assembly
- Machines to Ser. No. 631796
- Machines to Ser. No. 631870
- Machines from Ser. No. 631797
- Machines from Ser. No. 631871
- and 409 Machines
Steering Circuit Schematic (409 Telemaster)

Electrics23 topics

Testing Specific Gravity
- Battery Testing
- General Description
- Service Precautions
- Charging Circuit Check
- Charging Test
- Removal and Replacement
- Starting Circuit Test
- Lucas M127
- Syncro Shuttle from Ser. No.630686
- Powershift from Ser. No. 630686
- Syncro Shuttle from Ser. No. 632700
- Powershift from ser. No. 632700
- Telemaster
- Panel Harness
- Main Harness
- Panel Harness
- Main Harness
- Panel Harness
- Main Harness
- Panel Harness
- Main Harness
- Cab and Engines Cover Harness

Service Tools9 topics

Service Tools Numerical List
- Section 2 - Hydraulics
- Section 4 - Body & Framework
- Section 5 - Engine
- Section 6 - Transmission
- Section 7 - Axles
- Section 9 - Hydraulic Steering
- Section 10 - Electrics
Sealing and Retaining Compounds

Inside this manual

Real pages from this service manual (457 pages). Open the sample pages (PDF, 341 KB)

Sample pages from the JCB 406, 407, 408, 409, 409 Telemaster Wheel Loader Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page, Foldout diagram

Specifications, page 112: Engine
Troubleshooting, page 196: POWERSHIFT FAULT FINDING - INTRODUCTION
Diagram, page 357: Electrics
Color page, page 37: Hydraulics
Color page, page 328: Because the pump flow is always greater than the
Foldout diagram: Issue 1

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 457 pages

Quantity one is the manual described above.

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Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).