JCB 406, 409 (Tier 3) Operator Manual 9811-6900

Description

• Model List:
  • 406, 409 (Tier 3)

• 1. Safety Notices
• 2. Important Information ……………………………………………………………………….. vi
• 3. The Operator Manual …………………………………………………………………… vi
• 4. Safety Warnings ………………………………………………………………………….. vi
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………1
• 7. Machine Model and Serial Number ………………………………………………….1
• 8. Using this Manual ………………………………………………………………………….1
• 9. Left Side, Right Side ………………………………………………………………………1
• 10. Cab-Canopy …………………………………………………………………………………1
• 11. Cross References ………………………………………………………………………….1
• 12. Machine Description …………………………………………………………………………..2
• 13. The JCB Wheeled Loader ………………………………………………………………2
• 14. Intended Use ………………………………………………………………………………..2
• 15. Component Location ……………………………………………………………………..2
• 16. Safety Check List ……………………………………………………………………………….4
• 17. Safety – Yours and Others ………………………………………………………………4
• 18. General Safety ……………………………………………………………………………..4
• 19. Operating Safety …………………………………………………………………………..6
• 20. Maintenance Safety ……………………………………………………………………….9
• 21. Safety Labels …………………………………………………………………………………..14
• 22. Introduction …………………………………………………………………………………14
• 23. Safety Label Identification …………………………………………………………….15
• 24. Part Numbers and Description ………………………………………………………16
• 25. Identifying Your Machine …………………………………………………………………..17
• 26. Machine Identification Plate ………………………………………………………….17
• 27. Component Identification Plates …………………………………………………….18
• 28. Machine Security ……………………………………………………………………………..21
• 29. Introduction …………………………………………………………………………………21
• 30. JCB Plantguard …………………………………………………………………………..21
• 31. Construction Equipment Security And Registration Scheme (CESAR) .21
• 32. LiveLink ……………………………………………………………………………………..21
• 33. Operation
• 34. Introduction ……………………………………………………………………………………..23
• 35. Before Entering the Cab ……………………………………………………………………24
• 36. Entering and Leaving the Cab ……………………………………………………………25
• 37. Emergency Exit …………………………………………………………………………..26
• 38. Doors and Windows …………………………………………………………………………27
• 39. Opening and Closing the Door ………………………………………………………27
• 40. Opening and Closing the Windows ………………………………………………..28
• 41. Opening and Closing the Door Side Window …………………………………..28
• 42. Seat Controls …………………………………………………………………………………..29
• 43. Introduction …………………………………………………………………………………29
• 44. Standard Seat ……………………………………………………………………………..29
• 45. Air Suspension Seat …………………………………………………………………….30
• 46. Seat Belts ……………………………………………………………………………………….32
• 47. Inertia Reel Seat Belt …………………………………………………………………..32
• 48. Visibility Aids ……………………………………………………………………………………33
• 49. Mirrors ……………………………………………………………………………………….33
• 50. Cab Layout ……………………………………………………………………………………..34
• 51. Component Key …………………………………………………………………………..34
• 52. Drive Controls, Switches and Instruments ……………………………………………35
• 53. Drive Controls ……………………………………………………………………………..35
• 54. Switches …………………………………………………………………………………….39
• 55. Instruments …………………………………………………………………………………43
• 56. Air Conditioning and Heater Controls ……………………………………………..46
• 57. Operating Levers ……………………………………………………………………………..47
• 58. Introduction …………………………………………………………………………………47
• 59. Loader Arm Control Lever …………………………………………………………….48
• 60. Auxiliary Controls ………………………………………………………………………..49
• 61. Safety Equipment …………………………………………………………………………….51
• 62. Control Lever Locks …………………………………………………………………….51
• 63. Fire Extinguisher (if fitted) …………………………………………………………….52
• 64. Beacon ………………………………………………………………………………………52
• 65. Before Starting the Engine …………………………………………………………………53
• 66. Starting The Engine ………………………………………………………………………….55
• 67. Preparing The Machine For Travel ……………………………………………………..56
• 68. Introduction …………………………………………………………………………………56
• 69. Preparing for Road Travel …………………………………………………………….56
• 70. Preparing for Site Travel ……………………………………………………………….57
• 71. Smooth Ride System (Option) ……………………………………………………….57
• 72. Getting The Machine Moving ……………………………………………………………..58
• 73. Operating Practices ……………………………………………………………………..58
• 74. Operating Procedure ……………………………………………………………………59
• 75. Stopping and Parking the Machine ……………………………………………………..60
• 76. Working With The Machine ……………………………………………………………….61
• 77. Operating Practices and Site Safety ………………………………………………61
• 78. Safety Practices ………………………………………………………………………….61
• 79. Log Moving-Handling ……………………………………………………………………62
• 80. Danger Zone ………………………………………………………………………………62
• 81. Clothing and Safety Equipment ……………………………………………………..62
• 82. Working with a Shovel ………………………………………………………………….63
• 83. Working on Slopes ………………………………………………………………………65
• 84. Lifting (Object Handling) ……………………………………………………………….67
• 85. Operating Environment ……………………………………………………………………..69
• 86. Operating in Low Temperatures …………………………………………………….69
• 87. Operating in High Temperatures ……………………………………………………69
• 88. Operating in Dusty or Sandy Areas ………………………………………………..70
• 89. Operating in Coastal Regions ……………………………………………………….70
• 90. Operating on Wet or Soft Ground …………………………………………………..70
• 91. Cab Filters ………………………………………………………………………………….70
• 92. Refuelling the Machine ……………………………………………………………………..71
• 93. Low Fuel Levels ………………………………………………………………………….71
• 94. Filling the Tank ……………………………………………………………………………71
• 95. Moving A Disabled Machine ………………………………………………………………72
• 96. Introduction …………………………………………………………………………………72
• 97. Lower the Loader Arms in an Emergency ……………………………………….72
• 98. Towing the Machine ……………………………………………………………………..73
• 99. Recovery Hitch ……………………………………………………………………………73
• 100. Transporting the Machine ………………………………………………………………….74
• 101. Articulation Lock ………………………………………………………………………….76
• 102. Lifting the Machine …………………………………………………………………………..77
• 103. Storage of the Machine …………………………………………………………………….79
• 104. Introduction …………………………………………………………………………………79
• 105. Storage Area ………………………………………………………………………………79
• 106. Prepare the Machine for Storage …………………………………………………..79
• 107. Put the Machine into Storage ………………………………………………………..79
• 108. During Storage ……………………………………………………………………………79
• 109. Take the Machine Out of Storage …………………………………………………..80
• 110. Routine Maintenance
• 111. Service Requirements ………………………………………………………………………81
• 112. Introduction …………………………………………………………………………………81
• 113. Owner-Operator Support ………………………………………………………………81
• 114. Service-Maintenance Agreements …………………………………………………81
• 115. Initial Service and Inspection …………………………………………………………81
• 116. Fit for Purpose Tests for Lifting Equipment ………………………………………82
• 117. Obtaining Replacement Parts ………………………………………………………..82
• 118. Health and Safety …………………………………………………………………………….83
• 119. Lubricants …………………………………………………………………………………..83
• 120. Battery ……………………………………………………………………………………….85
• 121. Service Schedules ……………………………………………………………………………87
• 122. Introduction …………………………………………………………………………………87
• 123. How to Use the Service Schedules ………………………………………………..87
• 124. Calendar Equivalents …………………………………………………………………..87
• 125. Pre-Start Cold Checks, Service Points and Fluid Levels ……………………88
• 126. Functional Test and Final Inspection ………………………………………………91
• 127. Fluids, Lubricants and Capacities ……………………………………………………….93
• 128. Specifications ……………………………………………………………………………..93
• 129. Fuels ………………………………………………………………………………………….94
• 130. Tools ………………………………………………………………………………………………96
• 131. Tool Locations …………………………………………………………………………….96
• 132. Carrying Tools onto the Machine ……………………………………………………96
• 133. Prepare the Machine for Maintenance ………………………………………………..97
• 134. Introduction …………………………………………………………………………………97
• 135. How to Make the Machine Safe (Loader Arm Lowered) ……………………98
• 136. How to Make the Machine Safe (Loader Arm Raised) ………………………98
• 137. Safety Mechanism ……………………………………………………………………….99
• 138. Cleaning the Machine ……………………………………………………………………..101
• 139. Introduction ……………………………………………………………………………….101
• 140. Preparing the Machine for Cleaning ……………………………………………..102
• 141. Cleaning the Engine Cooling System ……………………………………………103
• 142. Checking for Damage ……………………………………………………………………..104
• 143. Check the Machine Body and Structure ………………………………………..104
• 144. Check the Seat and Seat Belt ……………………………………………………..104
• 145. Check the Hydraulic Hoses and Fittings ……………………………………….104
• 146. Check the Electrical Circuits ………………………………………………………..104
• 147. Check the Tyres ………………………………………………………………………..105
• 148. Checking the ROPS-FOPS Structure ……………………………………………105
• 149. Greasing ……………………………………………………………………………………….106
• 150. Introduction ……………………………………………………………………………….106
• 151. Preparing the Machine for Greasing …………………………………………….106
• 152. Loader Arms and Shovel …………………………………………………………….107
• 153. Articulation Pivot Points ………………………………………………………………108
• 154. Driveshaft Pivot Points ……………………………………………………………….108
• 155. Steering Pivot Points ………………………………………………………………….108
• 156. Quickhitch Locking-Pins ……………………………………………………………..109
• 157. Cab Door Hinges ……………………………………………………………………….109
• 158. Automatic Greasing System (if fitted) …………………………………………… 110
• 159. Access Panels ………………………………………………………………………………. 114
• 160. Introduction ………………………………………………………………………………. 114
• 161. Engine Cover ……………………………………………………………………………. 114
• 162. Heating and Ventilation ………………………………………………………………….. 115
• 163. Cleaning the Cab Heater Filter (machines without air conditioning) …. 115
• 164. Cleaning the Cab Heater Filter ……………………………………………………. 116
• 165. Cleaning the Cab Re-circulation Filter ………………………………………….. 116
• 166. Brakes …………………………………………………………………………………………. 117
• 167. Park Brake ……………………………………………………………………………….. 117
• 168. Foot Brake ……………………………………………………………………………….. 119
• 169. Electrical System ……………………………………………………………………………121
• 170. Battery ……………………………………………………………………………………..121
• 171. Jump Starting the Engine ……………………………………………………………122
• 172. Fuses and Relays ………………………………………………………………………124
• 173. Engine ………………………………………………………………………………………….127
• 174. Oil and Filter ……………………………………………………………………………..127
• 175. Drive Belt ………………………………………………………………………………….129
• 176. Air Filter ……………………………………………………………………………………132
• 177. Fuel System …………………………………………………………………………………..134
• 178. Introduction ……………………………………………………………………………….134
• 179. Fuel Filter …………………………………………………………………………………135
• 180. Sedimenter Bowl ……………………………………………………………………….136
• 181. Cleaning the Fuel Strainer …………………………………………………………..137
• 182. Priming the Fuel System …………………………………………………………….138
• 183. Hydraulic System ……………………………………………………………………………139
• 184. Introduction ……………………………………………………………………………….139
• 185. Release the Hydraulic Pressure …………………………………………………..139
• 186. Oil and Filters ……………………………………………………………………………140
• 187. Transmission …………………………………………………………………………………143
• 188. Transmission Drop-box (if fitted) ………………………………………………….143
• 189. Axles ………………………………………………………………………………………..145
• 190. Tyres and Wheels …………………………………………………………………………..148
• 191. Tyre Inflation ……………………………………………………………………………..148
• 192. Checking the Wheel Nut Torques …………………………………………………149
• 193. Windscreen Washers ……………………………………………………………………..150
• 194. Filling the Reservoir ……………………………………………………………………150
• 195. Fire Extinguisher (if fitted) ………………………………………………………………..151
• 196. Checking the Fire Extinguisher ……………………………………………………151
• 197. Optional Attachments
• 198. Introduction ……………………………………………………………………………………153
• 199. Attachments for your Machine ………………………………………………………….154
• 200. Quick Release Couplings ………………………………………………………………..155
• 201. Connecting and Disconnecting …………………………………………………….155
• 202. Quickhitch Control ………………………………………………………………………….157
• 203. Introduction ……………………………………………………………………………….157
• 204. Engage the Attachments …………………………………………………………….158
• 205. Disengage the Attachments ………………………………………………………..160
• 206. Specifications
• 207. Working Capacity …………………………………………………………………………..161
• 208. 406 ………………………………………………………………………………………….161
• 209. 409 ………………………………………………………………………………………….162
• 210. Static Dimensions …………………………………………………………………………..163
• 211. Turning Circles ………………………………………………………………………….163
• 212. 406 ………………………………………………………………………………………….164
• 213. 409 ………………………………………………………………………………………….166
• 214. Noise Data …………………………………………………………………………………….168
• 215. Introduction ……………………………………………………………………………….168
• 216. All Machines ……………………………………………………………………………..168
• 217. Vibration Data ………………………………………………………………………………..169
• 218. Introduction ……………………………………………………………………………….169
• 219. 406 ………………………………………………………………………………………….170
• 220. 409 (20 kph) ……………………………………………………………………………..171
• 221. 409 (40 kph) ……………………………………………………………………………..172
• 222. Tyre Sizes and Pressures ………………………………………………………………..173
• 223. Introduction ……………………………………………………………………………….173
• 224. Specifications ……………………………………………………………………………174
• 225. Warranty Information
• 226. Machine Service Record Sheet ………………………………………………………..175
• 227. Registration Information ………………………………………………………………….177
• 228. European Community Standards
• 229. EC Declaration of Conformity …………………………………………………………..179
• 230. Introduction ……………………………………………………………………………….179
• 231. Explanation of the EC Declaration of Conformity ……………………………181