JCB 406 (2504M Tier 3), 407, 409 (2504TCR Tier 4) KOHLER Engine Operator Manual 9821-9350

Description

• Model List:
  • 406 (2504M Tier 3), 407, 409 (2504TCR Tier 4) KOHLER Engine

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………3
• 7. Product Compliance ………………………………………………………………………3
• 8. Machine Model and Serial Number ………………………………………………….3
• 9. Using this Manual ………………………………………………………………………….3
• 10. Left Side, Right Side ………………………………………………………………………4
• 11. Cab-Canopy …………………………………………………………………………………4
• 12. Cross References ………………………………………………………………………….4
• 13. Machine Description …………………………………………………………………………..5
• 14. The JCB Wheeled Loader ………………………………………………………………5
• 15. Intended Use ………………………………………………………………………………..5
• 16. Component Location ……………………………………………………………………..5
• 17. Safety Check List ……………………………………………………………………………….7
• 18. Safety – Yours and Others ………………………………………………………………7
• 19. General Safety ……………………………………………………………………………..7
• 20. Operating Safety …………………………………………………………………………..9
• 21. Maintenance Safety ……………………………………………………………………..12
• 22. Safety Labels …………………………………………………………………………………..17
• 23. Introduction …………………………………………………………………………………17
• 24. Safety Label Identification …………………………………………………………….18
• 25. Part Numbers and Descriptions …………………………………………………….20
• 26. Identifying Your Machine …………………………………………………………………..21
• 27. Machine Identification Plate ………………………………………………………….21
• 28. Typical Product Identification Number ………………………………………….21
• 29. Component Identification Plates …………………………………………………….22
• 30. Engine Identification Number ………………………………………………………22
• 31. Transmission Identification Plate …………………………………………………22
• 32. Axle Identification Plates …………………………………………………………….23
• 33. FOPS Data Plate ………………………………………………………………………24
• 34. ROPS Data Plate ………………………………………………………………………24
• 35. Machine Security ……………………………………………………………………………..25
• 36. Product Compliance …………………………………………………………………….25
• 37. Introduction …………………………………………………………………………………25
• 38. JCB Plantguard …………………………………………………………………………..25
• 39. Construction Equipment Security And Registration Scheme (CESAR) .25
• 40. LiveLink ……………………………………………………………………………………..26
• 41. Operation
• 42. Introduction ……………………………………………………………………………………..27
• 43. Before Entering the Cab ……………………………………………………………………28
• 44. Entering and Leaving the Cab ……………………………………………………………29
• 45. Emergency Exit …………………………………………………………………………..30
• 46. Type A ……………………………………………………………………………………..30
• 47. Type B ……………………………………………………………………………………..31
• 48. Doors and Windows …………………………………………………………………………32
• 49. Opening and Closing the Door ………………………………………………………32
• 50. Opening and Closing the Windows ………………………………………………..33
• 51. Opening – Type A ………………………………………………………………………33
• 52. Closing …………………………………………………………………………………….33
• 53. Opening – Type B (If fitted) ………………………………………………………….34
• 54. To Close The Right Side Window: ……………………………………………….35
• 55. Opening and Closing the Door Side Window …………………………………..35
• 56. Seat Controls …………………………………………………………………………………..36
• 57. Introduction …………………………………………………………………………………36
• 58. Suspension Seat (KAB 100 Series – Mechanical) …………………………….37
• 59. Suspension Seat (KAB 100 Series – Air) …………………………………………38
• 60. Seat Belts ……………………………………………………………………………………….39
• 61. Inertia Reel Seat Belt …………………………………………………………………..39
• 62. Fasten the Seat Belt ………………………………………………………………….39
• 63. Check the Seat Belt is Operating Correctly …………………………………..39
• 64. Release the Seat Belt ………………………………………………………………..39
• 65. Visibility Aids ……………………………………………………………………………………40
• 66. Mirrors ……………………………………………………………………………………….40
• 67. Introduction ………………………………………………………………………………40
• 68. Adjusting the Mirror ……………………………………………………………………40
• 69. Side Mirrors ……………………………………………………………………………..41
• 70. Cab Layout ……………………………………………………………………………………..42
• 71. Component Key …………………………………………………………………………..42
• 72. Drive Controls, Switches and Instruments ……………………………………………44
• 73. Drive Controls ……………………………………………………………………………..44
• 74. Steering Wheel …………………………………………………………………………44
• 75. Steering Column Adjustment ………………………………………………………44
• 76. Accelerator Pedal ……………………………………………………………………..44
• 77. Foot Brake Pedal ………………………………………………………………………44
• 78. Park Brake Lever – 406 and 407 Machines Only ……………………………45
• 79. Park Brake Lever – 407HS and 409 Machines Only ……………………….45
• 80. Forward-Reverse Switch …………………………………………………………….46
• 81. Horn ………………………………………………………………………………………..47
• 82. Differential Lock (If Fitted). ………………………………………………………….47
• 83. Speed Switches ………………………………………………………………………..47
• 84. Rotary Throttle Control (Option) …………………………………………………..47
• 85. Multi-Purpose Steering Column Switch ………………………………………..48
• 86. Creep Speed Control …………………………………………………………………49
• 87. High Road Speed Machine (Option) …………………………………………….50
• 88. Switches …………………………………………………………………………………….50
• 89. Console Switches ……………………………………………………………………..50
• 90. Cab Interior Light ………………………………………………………………………53
• 91. Starter Switch ……………………………………………………………………………54
• 92. Constant Flow Switches ……………………………………………………………..54
• 93. Auxiliary Power Socket ………………………………………………………………54
• 94. Instrument Cluster – 406 Machines ………………………………………………..55
• 95. Introduction ………………………………………………………………………………55
• 96. Warning Lights ………………………………………………………………………….56
• 97. Instrument Cluster – 407 and 409 Machines ……………………………………58
• 98. Introduction ………………………………………………………………………………58
• 99. Warning Lights ………………………………………………………………………….59
• 100. Start-Up Screen ………………………………………………………………………..60
• 101. Status Screen …………………………………………………………………………..62
• 102. Set-Up Mode …………………………………………………………………………….63
• 103. Air Conditioning and Heater Controls ……………………………………………..65
• 104. Heater Controls …………………………………………………………………………65
• 105. Air Conditioning Controls (Option) ……………………………………………….65
• 106. Operating Levers ……………………………………………………………………………..66
• 107. Introduction …………………………………………………………………………………66
• 108. Control Lever Functions ……………………………………………………………….67
• 109. Overview ………………………………………………………………………………….67
• 110. Loader Arm Control ……………………………………………………………………..69
• 111. Loader Arm Float Control …………………………………………………………..70
• 112. Auxiliary Controls ………………………………………………………………………..71
• 113. Auxiliary Circuits Controls …………………………………………………………..71
• 114. Safety Equipment …………………………………………………………………………….74
• 115. Control Lever Locks …………………………………………………………………….74
• 116. Loader Arm Controls ………………………………………………………………….74
• 117. Fire Extinguisher (if fitted) …………………………………………………………….76
• 118. Operation …………………………………………………………………………………76
• 119. Beacon ………………………………………………………………………………………76
• 120. Fit the Beacon …………………………………………………………………………..76
• 121. Before Starting the Engine …………………………………………………………………77
• 122. Starting The Engine ………………………………………………………………………….79
• 123. Immobiliser (If Fitted) ……………………………………………………………………80
• 124. Keypad Immobiliser System ………………………………………………………….80
• 125. To Disarm the Immobiliser to Allow the Machine to be Used ……………80
• 126. To Disarm the Immobiliser ………………………………………………………….80
• 127. To Arm the Immobiliser ………………………………………………………………81
• 128. To Add a New or Additional PIN Code ………………………………………….81
• 129. To Delete All PIN Codes …………………………………………………………….81
• 130. 'Unique Key' Immobiliser System …………………………………………………..82
• 131. To Disarm the Immobiliser ………………………………………………………….82
• 132. To Arm the Immobiliser ………………………………………………………………82
• 133. To Add a New or Additional Starter key ………………………………………..82
• 134. To Remove the Program from a Starter Key ………………………………….82
• 135. Preparing The Machine For Travel ……………………………………………………..83
• 136. Introduction …………………………………………………………………………………83
• 137. Preparing for Road Travel …………………………………………………………….83
• 138. Preparing for Site Travel ……………………………………………………………….84
• 139. Smooth Ride System (Option) ……………………………………………………….84
• 140. Getting The Machine Moving ……………………………………………………………..85
• 141. Operating Practices ……………………………………………………………………..85
• 142. Limited Slip Differential (LSD) ……………………………………………………..85
• 143. Operating Procedure ……………………………………………………………………86
• 144. Stopping and Parking the Machine ……………………………………………………..87
• 145. Working With The Machine ……………………………………………………………….88
• 146. Operating Practices and Site Safety ………………………………………………88
• 147. Safety Practices ………………………………………………………………………….88
• 148. Log Moving-Handling ……………………………………………………………………89
• 149. Danger Zone ………………………………………………………………………………89
• 150. Clothing and Safety Equipment ……………………………………………………..89
• 151. Working with a Shovel ………………………………………………………………….90
• 152. Filling the Shovel ………………………………………………………………………90
• 153. Loading a Truck ………………………………………………………………………..91
• 154. Working on Slopes ………………………………………………………………………92
• 155. Introduction ………………………………………………………………………………92
• 156. Driving Up and Down Slopes ………………………………………………………92
• 157. Driving Across Slopes ………………………………………………………………..92
• 158. Lifting Operations on Slopes ……………………………………………………….93
• 159. Lifting (Object Handling) ……………………………………………………………….94
• 160. Safe Working Loads …………………………………………………………………..95
• 161. Operating Environment ……………………………………………………………………..96
• 162. Operating in Low Temperatures …………………………………………………….96
• 163. Operating in High Temperatures ……………………………………………………96
• 164. Operating in Dusty or Sandy Areas ………………………………………………..97
• 165. Operating in Coastal Regions ……………………………………………………….97
• 166. Operating on Wet or Soft Ground …………………………………………………..97
• 167. Tow Hitch (Option) ……………………………………………………………………………98
• 168. Introduction …………………………………………………………………………………98
• 169. Mechanical Tow Hitch …………………………………………………………………..99
• 170. Refuelling the Machine ……………………………………………………………………100
• 171. Low Fuel Levels ………………………………………………………………………..100
• 172. Filling the Tank ………………………………………………………………………….100
• 173. Moving A Disabled Machine …………………………………………………………….101
• 174. Introduction ……………………………………………………………………………….101
• 175. Lower the Loader Arms in an Emergency ……………………………………..101
• 176. Preparation For Towing ………………………………………………………………101
• 177. Front Recovery Point ………………………………………………………………….102
• 178. Rear Recovery Points ………………………………………………………………..102
• 179. Recovery Hitch – No Towing Hitch Fitted …………………………………….102
• 180. Recovery Hitch – (With Optional Towing Hitch) …………………………….103
• 181. Transporting The Machine ……………………………………………………………….104
• 182. Tie Down Restraint Requirements ………………………………………………..107
• 183. Articulation Lock ………………………………………………………………………..108
• 184. Transport Position ……………………………………………………………………108
• 185. Drive Position ………………………………………………………………………….108
• 186. Lifting a Machine ……………………………………………………………………………109
• 187. Storage of the Machine ………………………………………………………………….. 113
• 188. Introduction ………………………………………………………………………………. 113
• 189. Storage Area ……………………………………………………………………………. 113
• 190. Prepare the Machine for Storage ………………………………………………… 113
• 191. Put the Machine into Storage ……………………………………………………… 113
• 192. During Storage …………………………………………………………………………. 113
• 193. Take the Machine Out of Storage ………………………………………………… 114
• 194. Routine Maintenance
• 195. Service Requirements ……………………………………………………………………. 115
• 196. Introduction ………………………………………………………………………………. 115
• 197. Owner-Operator Support ……………………………………………………………. 115
• 198. Service-Maintenance Agreements ………………………………………………. 115
• 199. Initial Service and Inspection ………………………………………………………. 115
• 200. Fit for Purpose Tests for Lifting Equipment ……………………………………. 116
• 201. Obtaining Replacement Parts ……………………………………………………… 116
• 202. Health and Safety ………………………………………………………………………….. 117
• 203. Lubricants ………………………………………………………………………………… 117
• 204. Introduction ……………………………………………………………………………. 117
• 205. Hygiene …………………………………………………………………………………. 117
• 206. Storage …………………………………………………………………………………. 117
• 207. Waste Disposal ………………………………………………………………………. 117
• 208. Handling ………………………………………………………………………………… 117
• 209. First Aid – Oil ………………………………………………………………………….. 118
• 210. Spillage …………………………………………………………………………………. 118
• 211. Fires ……………………………………………………………………………………… 118
• 212. Battery …………………………………………………………………………………….. 119
• 213. Warning Symbols …………………………………………………………………….120
• 214. First Aid – Electrolyte ………………………………………………………………..120
• 215. Service Schedules ………………………………………………………………………….121
• 216. Introduction ……………………………………………………………………………….121
• 217. How to Use the Service Schedules ………………………………………………121
• 218. Calendar Equivalents …………………………………………………………………121
• 219. Pre-Start Cold Checks, Service Points and Fluid Levels ………………….122
• 220. Functional Test and Final Inspection …………………………………………….126
• 221. Fluids, Lubricants and Capacities ……………………………………………………..128
• 222. Specifications ……………………………………………………………………………128
• 223. Fuels ………………………………………………………………………………………..129
• 224. Acceptable and Unacceptable Fuels ………………………………………….129
• 225. Fuels for Low Temperatures ……………………………………………………..129
• 226. Biodiesel Fuel …………………………………………………………………………129
• 227. Tools …………………………………………………………………………………………….131
• 228. Tool Locations …………………………………………………………………………..131
• 229. Grease Gun ……………………………………………………………………………131
• 230. Wheel Brace …………………………………………………………………………..131
• 231. Carrying Tools onto the Machine ………………………………………………….131
• 232. Prepare the Machine for Maintenance ………………………………………………132
• 233. Introduction ……………………………………………………………………………….132
• 234. How to Make the Machine Safe (Loader Arm Lowered) ………………….133
• 235. How to Make the Machine Safe (Loader Arm Raised) …………………….133
• 236. Safety Mechanism ……………………………………………………………………..134
• 237. Install the Maintenance Strut …………………………………………………….134
• 238. Stow the Maintenance Strut ………………………………………………………135
• 239. Cleaning the Machine ……………………………………………………………………..136
• 240. Introduction ……………………………………………………………………………….136
• 241. Detergents ……………………………………………………………………………..136
• 242. Pressure Washing and Steam Cleaning ……………………………………..136
• 243. Preparing the Machine for Cleaning ……………………………………………..137
• 244. Cleaning the Engine Cooling System ……………………………………………138
• 245. Preparation …………………………………………………………………………….138
• 246. Using Compressed Air ……………………………………………………………..138
• 247. Using Cold-Cleaning Compounds ……………………………………………..138
• 248. Using High-Pressure Water ………………………………………………………138
• 249. Checking for Damage ……………………………………………………………………..139
• 250. Check the Machine Body and Structure ………………………………………..139
• 251. Check the Seat and Seat Belt ……………………………………………………..139
• 252. Check the Hydraulic Hoses and Fittings ……………………………………….139
• 253. Check the Electrical Circuits ………………………………………………………..139
• 254. Check the Tyres ………………………………………………………………………..140
• 255. Checking the ROPS-FOPS Structure ……………………………………………140
• 256. Seat ……………………………………………………………………………………………..141
• 257. Greasing ……………………………………………………………………………………….142
• 258. Introduction ……………………………………………………………………………….142
• 259. Preparing the Machine for Greasing …………………………………………….142
• 260. Loader Arms and Shovel …………………………………………………………….143
• 261. Articulation Pivot Points ………………………………………………………………144
• 262. Driveshaft Pivot Points ……………………………………………………………….144
• 263. Steering Pivot Points ………………………………………………………………….144
• 264. Quickhitch Locking-Pins ……………………………………………………………..145
• 265. Cab Door Hinges ……………………………………………………………………….145
• 266. Access Panels ……………………………………………………………………………….146
• 267. Introduction ……………………………………………………………………………….146
• 268. Engine Cover …………………………………………………………………………….146
• 269. Opening the Engine Cover ……………………………………………………….146
• 270. Closing the Engine Cover …………………………………………………………146
• 271. Heating and Ventilation …………………………………………………………………..147
• 272. Cleaning the Cab Heater Filter (machines without air conditioning) ….147
• 273. Cleaning the Cab Heater Filter …………………………………………………….148
• 274. Cleaning the Cab Re-circulation Filter …………………………………………..148
• 275. Brakes ………………………………………………………………………………………….149
• 276. Park Brake ………………………………………………………………………………..149
• 277. Introduction …………………………………………………………………………….149
• 278. Testing the Park Brake – 406 & 407 Machines Only ……………………..150
• 279. Testing the Park Brake – 407HS and 409 Machines Only ………………151
• 280. Foot Brake ………………………………………………………………………………..152
• 281. Brake System Characteristics (407HS and 409) ………………………….152
• 282. Electrical System ……………………………………………………………………………153
• 283. Battery ……………………………………………………………………………………..153
• 284. Battery Disconnection-Connection ……………………………………………..153
• 285. Checking the Electrolyte Level ………………………………………………….153
• 286. Battery Isolator ………………………………………………………………………..154
• 287. Jump Starting the Engine ……………………………………………………………155
• 288. Fuses and Relays ………………..