JCB 406–409 & 409 Telemaster Wheel Loader Service Manual – 1980s–1990s (P/N 9803/4200)

JCB Service publication P/N 9803/4200, Issue 11 covers the 406, 407, 408, 409, and 409 Telemaster. The starting serial number 632700 applies to the 407 and 409. Unless a section states otherwise, 406 information also applies to the 407, and 408 information applies to the 409 and 409 Telemaster.

PDF Search, Bookmarks, and Diagram Detail

Finding text and reading schematics: Ordinary text searches are not usable because of the PDF's character encoding. Numbered bookmarks provide coarse navigation at 20-page intervals. Small wiring labels require zooming, and some diagrams need page rotation.

Supplied as one printable, 457-page PDF in English. The total includes the original cover, 14 contents pages, and the introduction.

Loader Hydraulics, Drivetrain Repair, and Electrical Diagnosis

These selected topics show the range of work covered rather than reproduce the full contents. Other examples include rivet-nut fitting and service of the optional Farr Rotopamic air filter.

• Engine service: Perkins diesel maintenance, fuel-system bleeding, cooling-system service, and engine removal and reinstallation.

• Hydraulics and steering: Sundstrand pump inspection, loader-valve overhaul, relief-valve pressure tests, ram service, and Danfoss Orbitrol steering-unit repair.

• Transmission repair: Syncro Shuttle and Powershift disassembly, clutch-pack overhaul, torque-converter stall tests, and pressure, flow, and clutch-leakage testing.

• Axles and brakes: Hurth and JCB axle repair, differential setup, hub service, brake bleeding, and accumulator-charge-valve testing.

• Cab and loader structure: Cab removal, directly bonded glass replacement, center-pivot overhaul, Quickhitch service, and Telemaster boom-pad adjustment.

• Electrical diagnosis: Starting and charging tests, wiring diagrams, harness lists, transmission-control troubleshooting, and Safe Load Indicator adjustment and component testing.

Written for JCB distributor service engineers who have received or are receiving JCB training and already understand hydraulic-equipment repair and workshop safety.

Engine Service and Repair Scope

Engine data distinguishes the Perkins D3.152 from the 1004-4LR2, including injection-pump settings and compression, valve-clearance, and oil-pressure specifications. The 407 IND has a separate injection-pump setting from other 407/409 applications.

Engine work in this file covers servicing and removal/reinstallation; internal engine overhaul requires separate engine manuals. The engine section refers to publication 9806/0052 for the D3.152 and 9806/0100 for the 1004-LR. Maintenance references include multigrade oil requirements, antifreeze mixtures, service schedules, and illustrated grease-point locations.

Hydraulic, Steering, and Brake Diagnosis

Hydraulic coverage includes CETOP circuit schematics, loader-valve operating diagrams, and Typical Ram Operation cutaways. Telemaster sections explain boom compensation and hose-burst protection, with separate main, auxiliary, and servo pressure checks.

Pump inspection distinguishes external-leak resealing from pump-section replacement when output cannot be restored through relief-valve correction. Abrasive cleaning of Sundstrand gears or bearing blocks can destroy critical manufacturing dimensions.

The Brake Circuit Schematic for the 407/409 supports accumulator-charge-valve and foot-brake diagnosis. Separate bleeding procedures distinguish the 406 with Hurth axles, 406/408 with JCB axles, and 407/409 brake systems; steering coverage includes priority-valve operation and Orbitrol assembly.

Transmission and Axle Overhaul

Step-by-step disassembly and assembly instructions cover the Powershift input and reverse clutch packs, mainshaft, and layshaft. Powershift Drivepaths diagrams identify engaged clutch packs and active solenoids.

Fault-finding charts address loss of drive, abnormal stall speed, low pressure, and overheating. The Analogue Control Unit section adds electrical input/output testing with test kit 892/00885.

The Powershift installation reverses the relationship between clutch names and machine travel direction. That explanation helps technicians match a directional fault to the correct clutch circuit before selecting a test.

Axle sections distinguish Hurth units, JCB PD40/PD55 axles, and JCB differentials with or without limited slip. Exploded views and the Crownwheel & Pinion Meshing Diagram support bearing-preload, pinion-depth, and backlash work.

The JCB axle assembly notes warn that excessive pinion rolling torque distorts the collapsible spacer, requiring replacement. General UNF Grade S and metric Grade 8.8 torque tables supplement component-specific tightening data.

Cab, Boom, and Electrical Systems

Body procedures cover bonded glazing, standard and Farm Master low-roof cabs, center-pivot bearings, and Quickhitch versions with or without a power diverter. Telemaster boom tables relate wear-pad shims to clearance and fastener engagement.

Electrical diagrams and wire-by-wire harness lists distinguish transmission configurations and serial-number changes. The 409 Telemaster Circuit Diagram includes boom-control solenoids and the Safe Load Indicator.

SLI testing uses test box 892/00905 to separate readout-box, transducer, and harness faults after unsuccessful calibration. Balance and full-scale adjustment are documented separately from the readout-box functional test.

Follow the manual's precautions for raised booms, hydraulic pressure, and heavy assemblies. Its safety section also addresses hazardous decomposition of fire-damaged fluoroelastomeric seals.

A Sample of Cooling and Relief-Valve Data

The cooling-system tables list 12.5 liters for the 406 and 15.5 liters for the 408.

Main relief-valve operating pressures are 186 bar for the 406/407 and 207 bar for the 408/409 and 409 Telemaster; the corresponding main relief-valve pressure tests specify maximum engine speed.