jcb 406, 407, 409 Quick Start Manual

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Page 1

Quick Start Guide

Compact Wheeled Loader

406, 407 & 409

Page 2

Disclaimer Index

Intended Use ......................................................................................................................................4

This Quick Reference Guide is to provide quick and simple information to the Operator

and does not include any health and safety aspects. In addition, because of our continual

development of machines, features described in this Quick Reference Guide may differ

from those on your machine. No errors and emissions be entirely ruled out.

Dimensions ....................................................................................................................................5-7

Tie Down/ Lifting Points .....................................................................................................................8

Lifting Points ................................................................................................................................. 9 -10

This Quick Reference Guide DOES NOT replace the Operators Manual. You MUST

read ALL the disclaimers and safety and other instructions in the Operators Manual

before initially operating this product. Accordingly, no legal claims can be entertained on

the basis of the data, illustrations or descriptions in this Quick Reference Guide.

This machine should not be operated by any person who isn’t appropriately qualiﬁed or

had the appropriate training.

Operation of this machine without periodic maintenance could cause it to malfunction.

For more information please contact your JCB Dealer.

Cab Layout & Controls ................................................................................................................11-19

Start Up Sequence ...........................................................................................................................20

Shutdown Sequence .........................................................................................................................21

Maintenance Position ........................................................................................................................22

Service/ Maintenance ..................................................................................................................23-25

Fluids & Lubricants ............................................................................................................................26

Attachments .....................................................................................................................................27

Troubleshooting/ FAQs .....................................................................................................................28

Your Notes .................................................................................................................................29-31

23Please see operator manual for full details.

406, 407 & 409

Page 3

Intended Use Dimensions

General

> Machine Type – Compact Wheeled Loader

> 406,407 &409 front end ar ticulated Loader

Intended Use

> Machine intended to be used in normal conditions

> With bucket ﬁtted, machine work cycle consists of digging and discharging of materials

> Applications include earthmoving, road construction, building and construction, landscaping etc.

> Can be used for object handling

> Not intended for use in mining and quarrying applications, demolition, forestry and any

explosive atmospheres

> Must not be used with attachments of unknown weight, used on surfaces with unknown stability

– list not exhaustive

> PPE may be required in certain applications/environments e.g. high silica concentration or asbestos

> The machine should not be operated by any person who isn’t appropriately qualiﬁed or had the

correct training

> Prior to use, the machines suitability should be considered with regards to the intended applications

and any hazards which may be present

Fig 1

Machine model 406 407 409

A Overall length mm 5133 5133 5465

B Axle to pivot pin mm 906 906 1130

C Wheelbase mm 2100 2100 2205

D Axle to counterweight face mm 1268 1268 1295

E Ground clearance mm 313 313 472

F Width over cab mm 1468 1468 1468

G Width over tyres mm 1727 1727 1898

H Wheel track mm 1390 1390 1490

J Height over cab mm 2500 2500 2643

Front axle weight kg 1475 1395 1850

Rear axle weight kg 3398 3668 4076

Total weight kg 4873 5063 5926

Engine

Mechanical 36kW

(49hP)

Transmission Hydrostatic 2 Speed Hydrostatic 2 Speed

JCB Kohler

Mechanical 48kW

(64hP)

JCB Kohler

Mechanical 55.4kW

(74hP)

Hydrostatic 2 Speed

(Option 3 speed)

Axles Dana III Dana III Dana III

45Please see operator manual for full details.

406, 407 & 409

Page 4

Dimensions Dimensions

Fig 2 Fig 3

Machine model 406 407 409

M Dump angle maximum degrees 45 45 45

N Roll back angle full height degrees 56 56 63.6

O Roll back at carry degrees 54 54 53.1

P Roll back at ground level degrees 42 42 41

Q Load over height mm 2991 2991 3189

Dump height

(45 deg dump)

S Dig depth mm 105 105 60

T Reach at dump height mm 764 835 599

Pin height mm 3120 3120 3340

Bucket type General purpose General purpose General purpose

Bucket equipment Teeth or toeplate Teeth or toeplate Teeth or toeplate

Bucket capacity (SAE heaped)

Bucket weight kg 287 322 358

Tipping load straight kg 4225 4245 4503

Tipping load full turn kg 3250 3265 3584

mm 2489 2418 2552

m³ 0.8 1 1.2

Machine model

A Reach at ground level mm 710 710 724

B Reach at arms horizontal mm 1232 1232 1187

C Below ground level mm 84 84 17

D Arms, horizontal height mm 1426 1426 1396

E Arms, max. height mm 3012 3012 3231

Reach at

maximum height

Payload* kg 2033 2142 2366

Tipping load straight kg 3184 3324 3787

Tipping load full turn (40°)

Attachment weight kg 191 191 191

Fork carriage width mm 1345 1345 1345

Length of tines mm 1200 1200 1200

* At the centre of gravity distance 500mm. Based on 80% of FTTL as deﬁned in IS0 8313.

** FFTL from Calculation may vary after test work

Manual fork spacings at 50mm increments. Fork section 100mm x 50mm.

406 407 409

506 506 231

2541 2600 2907

67Please see operator manual for full details.

406, 407 & 409

Page 5

Machine Transport Proceedure

Operation

Lifting a Machine

Operation

Transporting The Machine

Operation

Transporting The Machine

T070350-27

Fig 78. Front Axle

Operation

Transporting The Machine

T070350-27

Fig 78. Front Axle

T070350-28

Fig 79. Rear Axle

Operation

Transporting The Machine

Operation

Transporting The Machine

Lifting Points

Fig 4

Note: These Measurements are based on

a 2500mm wide trailer bed. The correc t Tie

down points are Identiﬁed by their Labels.

A Restraint Angular Range 8° to 11°

B Restraint Angular Range 40° to 50°

C Front axle

D Rear axle

E Tie Down Restraint

F Tie Down Point

Fig 6

To Lift the Machine

All attachments need to be removed

2. Lower Boom

3. Remove all loose Items from machine

4. Check Un-laden weight

5. Use ONLY indicated Lift points (A)

6. Ensure the machine Is Balanced.

B B

Front Axle

Rear Axle

REFER TO OPER ATORS MANUAL TRANSPORTING MACHINE

89Please see operator manual for full details.

Fig 5

Tie Down Point Decal

406, 407 & 409

Page 6

Lifting Points Cab Layout

Operation

Lifting a Machine

Operation

Lifting a Machine

T070350-31

Fig 84. Lifting (Side View)

Operation

Cab Layout

Operation

Cab Layout

Operation

Drive Controls, Switches and Instruments

Park Brake Lever - 406 and 407 Machines Only

Important: No attempt must be made to adjust the park brake using the lever handle. The handle adjustment must remain permanently screwed all the way in.

1 Use this lever to engage the park brake 5 before

leaving the machine. K

Fig32.(T 42)

Park Brake Lever - 407HS and 409 Machines Only

1 You must apply the park brake C before you leave the

cab. K

Fig32.(T 42).

Operation

Drive Controls, Switches and Instruments

cab. K

Fig32.(T 42).

Fig 7 Fig 8

A H beam lifting spreader

B Centre line - centre of gravity

C Centre line - machine lifting point

D Lifting chain 5° minimum angle

E Lifting Chain 15° maximum angle

F Lifting chain 5° minimum angle

(To avoid damaging the machine)

G Lifting chain 15° Maximum angle

1011Please see operator manual for full details.

H Centre of gravity (For illustration only -

the position on your machine may var y)

J 0° angle maximum (Not shown)

K 5° Maximum angle

L Front of machine

M Rear of machine

N Perpendicular line - machine lifting point

P Lifting chain

406 & 407

Aux

rpm

1870

09876.4

mph

26.5

121314

409 O N LY

1. Steering Wheel

2. Accelerator pedal

3. Foot Brake

4. Forward/ Reverse Switch

5. Park Brake Lever

6. Instrument Cluster

7. Right Hand console

8. Operating Levers

9. Ignition Switch

10. Creep Speed

11. Rotary Throttle (Option)

12. Horn

13. Multi Purpose Steering

Column Switch

14. CAB Interior Light

15. Speakers

16. Front Window Blind

17. Steering column Adjustment.

406, 407 & 409

Page 7

Cab Console Front – 406 Cab Console Front – 407 & 409

Operation

Drive Controls, Switches and Instruments

Operation

Drive Controls, Switches and Instruments

Fig 9 Fig 10

406

13 15 17

12 14 16 18 19 20

31 2 84 5 6 7 9 10

1. Engine coolant temperature.

2. Engine Air Filter

3. Transmission oil Temperature

4. Transmission Error/Fault

5. High Speed Roading

6. Operator out of seat

7. Trailer Direction indicators

8. Rear Fog Light

9. SRS If ﬁtted

10. High Speed Warning

11. Reverse Warning Light

12. Battery /Alternator no charge

13. Engine Oil Pressure

14. Water in fuel

15. Engine Pre-heat

16. Hour meter

17. Main Beam

18. Park Brake

19. Low speed warning

20. Forward direction Warning

21. Fuel Level

22. Direction Indicators

23. Hazard Warning

407 & 409

Bat tery/ Alternator No Charge

2 3

26.5

2. Transmission Error/Fault (High Speed only)

/Transmission Error Faults (Non High speed)

3. Transmission oil Temperature

4. Park Brake

5. Engine ECU Fault/ Stop

6. Engine Pre-Heat

7. Engine Fault

8. Engine Oil Pressure

9. Engine Air Filter

10. Water In Fuel

11. Smooth Ride system

12. Hydraulic Error/Fault

Aux

rpm

1870

09876.4

mph

13. Transmission oil Pressure

14. Foot Brake

15. Fuel Level

16. Engine Coolant Temperature

17. Rear Fog Light

18. Main Beam

19. Trailer Direction Indicators

20. Direction Indicators

21. Hazard warning

A LCD Display

B Fuel Level Gauge

C Engine Temperature Gauge

1213Please see operator manual for full details.

406, 407 & 409

Page 8

Switching Options Start Up Sequence

Operation

Cab Layout

Operation

Cab Layout

Joys tick  Is olation

Gear Chang eSw itch

(High S peed)

Operation

Seat Belts

described.

tug. The seat belt should 'lock'.

!MWARNING

Operation

Starting The Engine

2 Press the MD button.

3 Enter your six digit master code using the keypad and

then press the ENT button.

4 The LED will flash three times to indicate acceptance

of the code.

5 Within 59 seconds of the three flashes press the MD

button.

6 Enter your four digit PIN number using the keypad

and then press the ENT button.The LED will flash four

Operation

Drive Controls, Switches and Instruments

Constant Flow Switches

Constant Flow

Right Console Switches ( T 51)

Setting the constant flow to ON gives constant forward flow only. “Aux 2 “ and the padlock symbol will appear on the dashboard display panel.

The flow can be stopped momentarily by operating the right side roller switch on the joystick.

To stop the constant flow, set the constant flow switch to OF F.

Note: The engine will not crank with the constant flow switch set to ON.

Constant Flow with High Flow (If Fitted)

Right Console Switches ( T 51)

High flow gives constant high flow and will only work when the constant flow switch is set to ON.

To stop the high flow, set the high flow or the Aux 2 switch to OFF.

Note: If the pressure gets too high in the system, the high flow will turn off automatically.

Auxiliary Power Socket

The socket can provide a 12V DC power supply (from the battery) to an electrical accessory.

Only connect an electrical accessory which is compatible with the power rating of the socket. The limits for the circuit are 7.5A continuous with an intermittent 10A.

Always run the engine during the prolonged use of an electrical accessory, otherwise the battery can discharge.

Operation

Starting The Engine

To Add a New or Additional Starter key

Note: Starter keys can be programmed to start more than one machine.

1 Put the master key in the starter switch then turn the

starter switch to position I. The LED will flash 3 times.

2 Turn the starter switch to position 0 then remove the

master key.

3 Put a new or an additional starter key in the starter

switch then turn the starter switch to position I. The LED will flash 4 times to confirm the starter key has been added.

Operation

Drive Controls, Switches and Instruments

Right Console Switches

Joystick Isolation (if fitted)

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Position 1: OFF (Backlight OFF)

Position 2: ON (Backlight ON)

Rear Fog Light (if fitted)

340051-1

Three position self-centring rocker switch. The switch functions only operate when the starter switch and the Side Lights and Headlights switch are in the ON position 2.

Position 1: OFF (Light-bar OFF)

Position 3: Default (Light-bar OFF)

Position 2: ON (Light-bar ON)

Operation

Drive Controls, Switches and Instruments

Cab Interior Light

T2-020

Press either end of the light unit A to switch on the cab interior light. Pressing the other end will switch the light off.

Make sure the light is turned off when you intend to leave the machine for a long period of time.

C007130-1

Fig 41.

Front Work Light (if fitted)

340100-1

Two position rocker switch. The switch functions operate when the starter switch is in the ON position.

Position 1: OFF (Light-bar OFF)

Position 2: Work Light ON (Light-bar ON)

Front and Rear Work Lights (if fitted)

333-L2606

Three position rocker switch. The switch functions operate when the starter switch is in the ON position.

Position 1: OFF (Light-bar OFF)

Position 2: ON (Light-bar ON) Front worklight.

Position 3: ON (Light-bar ON) Front and rear worklights.

Note: The work lights operate independently of the main lights circuit.

Beacon

Two position rocker switch. The switch functions operate when the starter switch is in the ON or OFF positions.

Position 1: OFF (Light-bar OFF)

Position 2: ON (Light-bar ON)

Roof

Fig 11

Front Work Ligh t

Rear Auxiliary

Right Hand Console

Fig 12

Q-Hitc h Locking

Pin Isolat or

Joystick Isolation

Constan t Flow

Selector

1415Please see operator manual for full details.

Front & Rear

Work Lights

Flashing B eacon

Rear Wipe r Side l ights &

Gear Cha nge Switch

(High Spee d)

Constan t Flow

Selecto r High Flow

Rear Fog Lig ht 2 Speed

Headlights

Hazard L ights

Smooth Ri de

System

(Creep Spe ed Option)

Aux

1870

09876.4

mph

26.5

1213141718

rpm

Insert Isolator Key

Isolator Key Located either outside

or Under Bonnet.

Key on & Dis Arm Immobiliser

Coded Key (Option) or Key Pad.

See Immobiliser Section

Start Machine

Turn Key though to position S once started key

will spring Back to IGN position.

Apply Seat Belt, Check Neutral Controls

Check all Levers are in neutral position

and fasten seatbelt.

Engine Pre- Heat

Hold key in Position 1 for approximately

2-3 Secs and then start.

Activate Controls & Beacon

Independent Beacon switch.

Press Isolator switch to activate Controls.

406, 407 & 409

Page 9

Fig 35. ( T 46).

– Forward, push the switch forward.

– Reverse, pull the switch back.

– Neutral, put the switch in its central position.

direction. K

Fig35.(T 46).

!MCAUTION

C051330-C4

Fig 37.

Tabl e 1.

Note: See the joystick operation decal fitted to your machine.

Rotary Throttle Control (Option)

!MWARNING

C Tortoise - Used for low speed

operations (for example loading). Push the button to select this mode. The hare icon will go OFF and the tortoise icon (on the front console) will come ON.

D Hare - Used for high speed operations

(for example roading). Push the button to select this mode. The hare icon on the front console will come ON.

Operation

Drive Controls, Switches and Instruments

SW-001_2

Machine Operation

Operation

Drive Controls, Switches and Instruments

Directional Control on Main Joystick

Fig 13

A Direction Switch

B Horn

C Tortoise Switch

D Hare switch.

Creep Speed

Fig 14

1. Select Creep Speed.

2. Select Forward drive.

3. Adjust Road speed adjust Knob A.

4. To Lock Setting Turn thumb wheel below

clockwise, to unlock turn counter clockwise.

High Road Speed (option)

Fig 15

1. Travel in Hare mode approximately 6-20 kph.

When display shows “+” High speed can

be selected.

2. Push the gear change switch and High speed

will be selected. Highway Icon shows on dash

3. Machine is in High speed until deselected.

1617Please see operator manual for full details.

To change Back to Hare Mode

1. Travel at 6-10 KPH. The “-” symbol will

display adjacent to motorway symbol.

2. When the Gear change Icon is “On”

push the switch to engage Hare speed.

406, 407 & 409

Page 10

Machine Operation

Operation

Operating Levers

Control Lever Functions

Overview

The information label is adjacent to the servo-control lever and gives an overview of its functions. The label information depends on the specification of your machine.

Fig50.(T 67), K Fig51.(T 67), K Servo Controls Decal ( T 68) and K Servo Controls Decal With Differential Lock ( T

68).

Note: Button C is a machine option and the logo will only

be shown on the decal if the diff lock is fitted.

Differential Lock (If Fitted). ( T 47).

Manual Control Machines (406 and 407)

T070350-47B

Fig 51. Manual Controls Decal With Differential Lock

Table 3. Manual Controls

A Single spool control configuration

B Twin Spool Control Configuration

C Single spool configuration with optional

locking differential.

D Twin spool configuration with optional locking

differential.

E Machine Option (Diff Lock) K

Differential

Lock (If Fitted). ( T 47)

F Tortoise / Hare Speed Range Switches

K Speed Switches ( T 47)

Operation

Operating Levers

Servo Control Machines (Optional 407 and 409)

Table 4. Servo Controls

A Single spool control configuration

B Twin Spool Control Configuration

C Single spool configuration with optional

locking differential.

D Twin spool configuration with optional locking

differential.

E Machine Option (Diff Lock) K

Differential

Lock (If Fitted). ( T 47)

F Tortoise / Hare Speed Range Switches

K Speed Switches ( T 47)

G Spool Control (First Auxiliary Spool)

H Spool Control (Second Auxiliary Spool - If

Fitted)

J Control Lever

Operation

Operating Levers

Servo Control Machines (Optional 407 and 409)

T070350-48A

Fig 52. Servo Controls Decal

Table 4. Servo Controls

A Single spool control configuration

B Twin Spool Control Configuration

C Single spool configuration with optional

locking differential.

D Twin spool configuration with optional locking

differential.

E Machine Option (Diff Lock) K

Differential

Lock (If Fitted). ( T 47)

F Tortoise / Hare Speed Range Switches

K Speed Switches ( T 47)

G Spool Control (First Auxiliary Spool)

H Spool Control (Second Auxiliary Spool - If

Fitted)

J Control Lever

Operation

Operating Levers

Operation

Operating Levers

Operation

Operating Levers

Fig 16 Fig 18

406

Manual Controls Decal

A Single Spool Control Conﬁguration

B Twin Spool Control Conﬁguration

C Single Spool conﬁguration with optional

Locking differential.

D Twin Spool conﬁguration with optional

Locking differential.

Fig 17

407 & 409

A Single Spool Control Conﬁguration

B Twin Spool Control Conﬁguration

C Single Spool conﬁguration with optional

Locking differential.

D Twin Spool conﬁguration with optional

Locking differential.

Servo Controls Decal Servo Controls Decal With Differential Lock

1819Please see operator manual for full details.

Manual Controls Decal With Differential Lock

E Machine Option (Diff lock)

F Tortoise/Hare Speed Range switches

G Spool Control

H Spool Control (Second Aux)

J Control Lever.

E Machine Option (Diff lock)

F Tortoise/Hare Speed Range switches

G Spool Control

H Spool Control (Second Aux)

J Control Lever.

Arm Raise

2. Arm Lower

3. “Float”

4. Empty “Dump”

5. Fill “Crowd”

CAUTION: Do not use the ‘ﬂoat function’ as a return to ground Detent. This can Cause Damage to Machine, cause instability

and Injury to the Operator.

406, 407 & 409

Page 11

Fig 130. ( T 190).

T070350-21

Fig 131. Auxiliary Lever (If fitted)

T070350-23

Fig 132. Servo Control Lever (If fitted)

Optional Attachments

Quickhitch Control

806070-6

Fig 126.

T070350-21

Fig 127. Auxiliary Lever (If fitted)

T070350-22

Fig 128. Servo Control Lever (If fitted)

Optional Attachments

Quickhitch Control

806070-6

Fig 126.

Optional Attachments

Quickhitch Control

806070-6

Fig 126.

T070350-21

Operation

Drive Controls, Switches and Instruments

leaving the machine. K

Fig32.(T 42)

Park Brake Lever - 407HS and 409 Machines Only

1 You must apply the park brake C before you leave the

cab. K

Fig32.(T 42).

Operation

Entering and Leaving the Cab

Operation

Entering and Leaving the Cab

Operation

Operating Levers

Operation

Starting The Engine

To Add a New or Additional Starter key

Note: Starter keys can be programmed to start more than one machine.

1 Put the master key in the starter switch then turn the

starter switch to position I. The LED will flash 3 times.

2 Turn the starter switch to position 0 then remove the

master key.

3 Put a new or an additional starter key in the starter

switch then turn the starter switch to position I. The LED will flash 4 times to confirm the starter key has been added.

Machine Operation – Q-Hitch Shut Down Sequence

Fig 19 Fig 21

Press and hold Q-hitch Switch

and activate to “Unlock hitch”

and release.

Q-Hitc h Locking

Pin Isolat or

Locate Pin A into attachment and raise slightly.

Then Crowd attachment onto Hitch Ensuring

good location of Pin C into D.

Stop Machine

Park machine on dry Level ground.

Apply Park Brake, Check Neutral

Bring the machine to a safe stop. Apply Hand

brake and place transmission in Neutral.

Fig 20 Fig 22

Operate Aux service to “lock on” attachment.

Test attachment is mated to machine.

2021Please see operator manual for full details.

Servo Control Lever (If ﬁtted)

Auxiliary Lever (If ﬁtted)

It is the responsibilit y of the operator to make sure

the machine is lef t in a safe & secure environment.

Lower Arm / Attachment

Place Bucket/Attachment on ground

and Isolate controls.

407 & 409

Key off & Remove

Turn Engine off, Turn to IGN on and Vent

Hydraulic system.

If Attachment requires Hydraulics coupling,

Lower attachment to ground level. Turn off

engine and vent Hydraulic system. Connect

couplings and route hoses safely, ensuring

Connectors are cleaned and secure.

Exit machine and Secure

Using 3 points of contact and then lock Door.

Remove Isolator Key

Isolator Key Located either outside

or Under Bonnet.

406, 407 & 409

Page 12

Maintenance Position

Routine Maintenance

Prepare the Machine for Maintenance

Routine Maintenance

Prepare the Machine for Maintenance

Service/Maintenance

Fig 23

Machine Maintenance should be carried out by trained and qualiﬁed personnel.

Ensure the machine is parked safe level ground and Isolated.

Daily Checks (10h) Checks

Condition of attachment / optional equipment Visual

Grease as required all points on machine (ref Operator handbook) Physical

Check machine condition latches bonnets, Visual / physical

Check in Cab switches and functions Visual/physical

Check engine bay Visual

Check engine oil Physical

Check hydraulic oil (sight glass) Visual

Check coolant levels Visual

Check fuel separator (Drain if necessar y) Visual / physical

Check coolant pack for dust debris Visual / physical

Check windscreen & washers ﬂuid level Visual / physical

Check operation of all services Physical

Check operation of key items horn lights beacon Visual / audible

Check operation of hour meter, Visual

Check tyres and pressures Visual / physical

Weekly Checks (50h) Check

Grease machine where necessar y Physical or Visual

Check tyres and tread Visual

Check machine hose and pipework Visual

Check ram condition Visual

1. Park machine In Either position A or B depending on task (position B requires safety strut).

2. Isolate and Vent machine, removing Key and Isolator.

2223Please see operator manual for full details.

406, 407 & 409

Page 13

Routine Maintenance

Electrical System

Routine Maintenance

Access Panels

T3-100

Important: Before you stop the engine, you must allow the engine to operate at low idle for four minutes. The delay allows the coolant temperatures to stabilise before you open the engine cover.

1 Make the machine safe with the loader arm lowered.

Refer to Prepare the Machine for Maintenance.

2 Unlock the security lock built into the release button

A. It is recommended that the cover is kept locked.

3 Press in the release button and allow the gas struts to

raise the cover.

Note: Your machine may differ slightly from that shown.

Closing the Engine Cover

1 Pull down the engine cover until the latch engages.

2 Make sure the cover is securely latched.

3 Lock the security lock and remove the key.

Access Covers

Routine Maintenance

Engine

Routine Maintenance

Engine

Cleaning the Air Filter Dust Valve (407 & 409 Machines)

Important: Do not run the engine with the dust valve K removed. K

Fig117.(T 167).

1 Make the machine safe with the loader arm lowered.

Refer to Prepare the Machine for Maintenance.

2 Open the engine cover.

3 Check the dust valve K is not blocked.

4 Inspect the rubber flaps for cuts and nicks and check

that the rubber is not perished. Renew if necessary.

5 Make sure that the air holes L are clear.

6 Close the engine cover.

Routine Maintenance

Engine

Routine Maintenance

Electrical System

Engine cover

Fig 24 Fig 29Fig 26

A Key lock (ignition key)

Hydraulic Oil & Washer Bottle

Fig 25

A Sight glass

B Hydraulic Oil Filler cap

C Washer Filler

Fig 27

Fig 28

A Air Filter

B Fuel Filter

Secondary Fuses and relays location

A Relays

B Secondary

Fuses

Coolant

A Filler

HOT

MAX

Engine Oil

A Engine Oil Dipstick

B Engine Oil Filler

Fig

2425Please see operator manual for full details.

COLD

MIN

Fig

406, 407 & 409

Page 14

Fluids and Lubricants Machine Attachments

Item

Fuel Tank 80 (17.6) Diesel

Engine (Oil) 406 Machines Only 4001/18 0 5 20 litres

Minimumw 11 (2.42)

Maximum 12 (2.64)

Engine (Oil) 407&409 Machines Only 4001/3005 20 litres

Minimum 11 (2.42)

Maximum 12 (2.64)

Front Axle (Includes Hubs)

Rear Axle (includes Hubs)

Hydraulic System 70 (15.4) JCB Hydraulic Fluid HP15 4002/0503 20 litres

Capacity

Litre (UK Gal)

4.4 (0.96) JCB Gear Oil HP 4000/0505 20 litres

6.05 (1.33) JCB Gear Oil HP 4000/0506 20 litres

Fluid / Lubricant

JCB Extreme Per formance

15W 40 (API CJ14,ACEA

E6-E9,Low SAPS) Caution Do

not use ordinary engine Oil

JCB Extreme Per formance

10W 40 (API CJ14,ACEA

E6-E9,Low SAPS) Caution Do

not use ordinary engine Oil

JCB Part

Number

Container

Size

Description Weight (kg) Intended Use

Q hitch

Shovel (406)

0.8 Cu metre 287 GP shovel

1.0 Cu metre 332 GP shovel

1.2 Cu metre 353 GP shovel

6 in 1 Cu metre 435 GP shovel

Q hitch forks 191 Unloading and movement

Shovel (407 & 409) GP shovel

0.8 Cu metre 287 GP shovel

1.2 Cu metre 353 GP shovel

1.4 Cu metre 384 GP shovel

To assist multi

attachment users

Hyrdaulic

Requirements

Aux ﬂow

Inching system

Grease points

Electrical Connections

Part of

Braking system

JCB Hydraulic Fluid HP15 4002/0503 5 litres

JCB Special HP grease or

JCB Special MPL-EP Grease

To Prevent corrosion and

moisture, Put Layer of

petroleum jelly on all exposed

2627Please see operator manual for full details.

6 in 1 Cu metre 435 GP shovel

4000/2505

4002/0503

connections

ATTACHMENT WEIGHTS ARE A GUIDE ONLY, ALWAYS CHECK YOUR OWN ATTACHMENTS

406, 407 & 409

Page 15

Troubleshooting/FAQs Your Notes

Issue / FAQ Resolution/Answer

Machine will not start

Machine Hydraulics will not operate

Code not excepted by immobiliser

Coded Key does not work

Qhitch does not unlock

Quick release couplings

do not engage

Ensure all functions are in neutral, High ﬂow is not engaged

and Hand brake is applied before starting.

Ensure Engine is running, Hydraulics have been

activated using the Isolation switch.

Joystick Isolation

Ensure code is current and entered correctly, Be sure sequence

is followed If locked out turn on ignition and leave for 15 minutes

the system will reset to try again with current codes

Ensure the key has not been near electrical items

The coded key is up to date

Use Coded key to re-programme extra keys

Check Machine battery has charge to turn machine over.

Check the Q hitch activation switch

Ensure Hydraulics are active

Check locking pins are free from debris and can mve freely check

electrical connections

Check all pressure has been vented from Machine

Check all pressure has been vented from attachment

(over time attachments can creep) please store all attachments

in the closed position.

Check coupling are free from contamination and dirt

Ensure Hand brake has been released

Machine will not drive

Check speed setting (start in Turtle)

If engaging motorway mode be sure to follow procedure safely

and seatbelt fastened.

2829Please see operator manual for full details.

406, 407 & 409

Page 16

Your NotesYour Notes

3031Please see operator manual for full details.

406, 407 & 409

Page 17

JCB Sales Limited, Rocester, Staffordshire, United K ingdom ST14 5JP

Tel: +44 1889 590312 Email: salesinfo@jcb.com

Download the very latest information on this product range at: www.jcb.com

All right s reserved. No p art of this pub lication may be rep roduced, stored i n a retrieval sys tem, or transmi tted in any form or by any other means, el ectronic, mech anical, photoco pying

or other wise, without p rior permissi on from JCB Sales . All references in t his publicati on to operating wei ghts, sizes, capa cities and other performance m easurements a re provided

for guida nce only and may var y dependant upo n the exact spec iﬁcation of the machine. They shou ld not therefore b e relied upon in rel ation to suitab ility for a par ticular applic ation.

Guidance and advice shoul d always be sought f rom your JCB Deale r’. JCB reserves the r ight to change spec iﬁcations wit hout notice. Ill ustrations an d speciﬁcatio ns shown may

include op tional equipm ent and accessori es.

9818/290 0