JCB 406 407 408 409 and 409 Telemaster Service Manual (9803/4200)

JCB 406, 407, 408, 409 & 409 Telemaster Service Manual (9803/4200 Issue 11)

This highly detailed workshop manual covers complete diagnostics, repair, and servicing procedures for the JCB 406, 407, 408, 409, and 409 Telemaster machines. From hydraulic and electrical schematics to engine servicing and drivetrain overhauls, the manual provides essential guidance for workshop technicians managing routine maintenance and in-depth technical interventions.

Model Covers:

This manual includes service instructions for the following models:

JCB 406 Wheel Loader

JCB 407 Wheel Loader

JCB 408 Wheel Loader

JCB 409 Wheel Loader

JCB 409 Telemaster Telescopic Handler

* 407 and 409 from Serial Number 632700

Note: Unless otherwise stated, procedures for 406 apply to 407, and 408 applies to 409 and the 409 Telemaster.

File Format: PDF

Size: 16.36 MB

No. of pages: 457

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Included Sections:

General Information

• Machine fluid types, capacities, torque settings, and greasing guides
• Routine maintenance intervals and full lubrication points

Hydraulic Systems

• Model-specific schematics, loader valve diagrams, check valve operation
• Component servicing for pumps, rams, and relief valve adjustments
• Full pressure testing and schematic cutaways for 406, 408, and 409 Telemaster

Body and Framework

• Cab glazing, loader arms, quickhitch systems and central pivot assemblies
• Detailed rivet nut fitting, boom shimming and structural inspection

Engine

• Servicing for D3.152 and 1004-LR engines, air/fuel filtration and cooling system
• Step-by-step engine removal, belt tensioning and fuel bleeding

Transmission

• Syncro Shuttle and Powershift transmission teardown and rebuild
• Clutch testing, stall test, flow diagnostics and ACU fault tracing
• Torque converter, solenoid testing and input/reverse clutch procedures

Axles

• JCB and Hurth axles - driveheads, LSD differentials, pinion meshing and hub work
• Illustrations and disassembly procedures for each axle type

Brakes

• Brake schematics, master cylinder repair, accumulator valve testing
• Bleeding procedures for various axle types and parking brake service

Hydraulic Steering

• Priority valve functions, steering unit testing and column disassembly
• Steering ram service based on serial range, including schematic review

Electrical Systems

• Complete electrical schematics per model and serial number
• Starter, alternator, ACU, battery testing and Safe Load Indicator diagnostics
• Wiring lists for cab, panel, auxiliary, and engine harnesses

Service Tools

• Numerical tool list by system, and sealing/retaining compound specifications

This JCB 406–409 Telemaster Service Manual is a complete resource for workshop mechanics handling loader diagnostics, hydraulic troubleshooting, and drivetrain servicing for compact and mid-sized JCB machines.