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

This comprehensive JCB Wheel Loader service manual covers models 406, 407, 408, and 409, providing detailed procedures for all powertrain and hydraulic systems. It includes troubleshooting guides.

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Document Details

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Document Number / Seller:
27767 / Ronald Torres
File Size:
84.94 MB
File Type:
PDF
Language:
English
Pages:
457
Printable:
Yes
Category:
Wheel Loader
Last updated / verified
Jan 23, 2026

Models Covered & Key Technical Specifications

JCB 406, 407, 408 & 409 Wheel Loader Service Manual (SN varies) – 400 Pages | OEM Specs #8140212 OEM-Documentation

Covers 406, 407, 408, 409 models with detailed procedures for disassembly, assembly, maintenance, and troubleshooting. Includes torque specifications for bolt stretch prevention.

  • Technical Data-Point: 9803/4200 defines the comprehensive service architecture for machine serial numbers starting from 632700.
  • Specific Measurement: 4102/1201 is required for medium strength sealing of all sizes of gasket flanges and hydraulic fittings.
  • Essential Rating: Medium strength must be maintained during the application of JCB Multi-Gasket A to ensure assembly integrity.
  • Advanced Parameter: Issue 11 establishes the latest technical revision standard for the designated earthmoving equipment range.
  • Core Limit: 25-65mm signifies the diameter threshold for which specific hydraulic fitting sealants are suitable within the system.
  • Torque Value: 47 Nm establishes the required torque for the primary mounting bolts.

    System coverage includes:

    Systematizing the service groups into: General Hydraulics Attachments Body and Framework Engine Transmission Axles Brakes Hydraulic Steering Electrics Service Tools This manual documents complete repair procedures for all major systems, ensuring users can effectively maintain and repair their JCB Wheel Loaders. It also details professional technical specifications for various components.

Professional Workshop Service Manual & Technical Specifications

JCB 406, 407, 408 & 409 Wheel Loader Service Manual (SN varies) – 400 Pages | OEM Specs #8140212 OEM-Documentation

Repair-Classification: Service Manual // Model-Portfolio: JCB 406, 407, 408, 409 (SN varies) / JCB 409 Telemaster // Engine-Type: Naturally Aspirated

Identifier Value Calibration-Spec
Technical Data 9803/4200 Issue 11 N/A
Engine 406 10.7 litres (2.4 UK gal)
Gearbox Synchro Shuttle 119 litres (4.2 UK gal)
Axes JCB 406 5.0 litres (1.1 UK gal)
Hydraulic System 406 63 litres (14.1 UK gal)
Cooling System 406 15.5 litres (3.5 UK gal)
Fuel System 406 90 litres (20.2 UK gal)

Systematizing the service groups into: General Hydraulics Attachments Body and Framework Engine Transmission Axles Brakes Hydraulic Steering Electrics Service Tools This manual documents complete repair procedures for all major systems, ensuring users can effectively maintain and repair their JCB Wheel Loaders. It also details professional technical specifications for various components.

FAQ

Specify the **lubrication** requirements for the JCB 406? keyboard_arrow_down

2.4 UK gallons (2.9 litres) of JCB Transmission Fluid is required for the gearbox, as per the specifications outlined on page 5-2.

What is the **exact** testing parameters for the hydraulic system? keyboard_arrow_down

63 litres (14.1 UK gal) of JCB Special Hydraulic Fluid is required for the hydraulic system, as detailed in the technical data section.

Calculate the **specific** diagnostic procedures for a "Low Mainline Pressure" fault? keyboard_arrow_down

15.5 litres (3.5 UK gal) of Water/Anti-freeze is specified for the cooling system, which must be checked and maintained according to the procedures on page 5-2.

What values **designated** for fluid capacity requirements are listed? keyboard_arrow_down

90 litres (20.2 UK gal) of Diesel oil is specified for the fuel system, which should be checked and maintained as per the diagrams provided.

Assess the **critical** component identification for the torque settings? keyboard_arrow_down

40 Nm (30 lbf ft) is the specified torque for the drive plate bolts, as detailed on page 8-1, ensuring correct torque settings.

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Reviews (2)

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New
The manual is incredibly thorough and easy to navigate. It made servicing my JCB 407 a breeze! Highly recommend for any operator.
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New
Rated 4 out of 5 stars