JCB 408 Wheel Loading Shovel Workshop Repair Service Manual

Service Manual 406 407 408 409 JCB SERVICE © ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND. TEL. ROCESTER (01889) 590312 Publication No. 9803/4200 Issue 11 Published by the Technical Publications Dept. of JCB Service, Rocester, Staffordshire, England. R

General 1 Hydraulics 2 Attachments 3 Body and Framework 4 Engine 5 Transmission 6 Axles 7 Brakes 8 Hydraulic Steering 9 Electrics 10 Service Tools 11 Contents 9803/4200 Issue 3* This Service Manual covers the following machines: 406 407 408 409 * 409 Telemaster 407 and 409 Machines commence from Serial Number 632700. Unless otherwise stated, information for 406 also applies to 407 and information for 408 also applies to 409 and the 409 Telemaster.

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving or have received training by the JCB Technical Training Department. It is assumed that such personnel have a sound knowledge of good workshop practice, safety procedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Details of such may therefore be omitted from this manual, the primary intention being to convey the more specialised information concerning particular aspects of the machine or component in question. Renewal of oil seals, gaskets, etc. and any component showing obvious wear or damage is expected. It is also expected that components will be thoroughly cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent entry of dirt and excessive loss of hydraulic fluid. For convenience the manual is compiled in sections, e.g. "Hydraulics", "Electrics" etc., but to find details of a specific component or its application, reference should be made to the alphabetical index at the back of the manual. Except where a maximum and minimum figure is given, torque settings quoted in the text are intended as 'mean' figures which may be varied by + or - 3%. Where no figure is quoted in the text, refer to page 1/1 - 3. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine looking forward. 9803/4200 Issue 3 ! WARNING Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1 Ensure that components have cooled then remove and place material into plastic bags. 2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. 3 Thoroughly wash contaminated area with detergent and water. 4 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1 ! WARNING Asbestos Asbestos dust can damage your lungs. Some engine joints and gaskets may contain asbestos. Take the following precautions when working on them. 1 Wear a face mask and gloves. 2 Work in a well ventilated area and do not smoke. 3 Do not use a rotary wire brush, use a hand scraper. 4 Make sure the material to be removed is wet with oil or water to contain loose particles. 5 Place all material into plastic bags and dispose of in accordance with local regulations. GEN-1-8

i 1 General 9803/4200 1 i Issue 3* Contents Page No. Fluids, Lubricants, Capacities & Specifications - 406/408 1 - 1 - 407/409 1 - 2 - 409 Telemaster 1 - 3 - Torque Settings 1 - 10 Service Schedules 2 - 1 Greasing - Shovel Pivot Pins 3 - 1 - Loader End 3 - 2 - Central Pivot and Steering Ram 3 - 3 - Intermediate Propshaft 3 - 3 - Propshafts (except Intermediate) 3 - 4 Greasing (409 Telemaster) - Boom Wear Pad Runways 4 - 1 - Boom Pivot Pins 4 - 2 * *

1 - 1 Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION Engine Oil 406 -18 to 0° C 7.2 litres (1.6 UK gal) JCB Torque Converter Fluid API CD MIL-L-2104C -10 to 50° C 408 JCB 15W/40 Multigrade 10.7 litres (2.4 UK gal) Gearbox Syncro Shuttle †19 litres (4.2 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Powershift †19 litres (4.2 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Transfer box 1.3 litres (0.3 UK gal) JCB HD 90 Gear Oil API-GL-5, MIL-L-2105C Axles - Hurth (406) Differential Housing 5.0 litres (1.1 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B Hubs (Individual) 0.2 litres (0.04 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B Axles - JCB 406 5.0 litres (1.1 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B 408 16 litres (3.6 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B Hydraulic System 406 Up to 38° C 59 litres (13.2 UK gal) JCB Special Hydraulic Fluid ISO 32 Above 38°C 408 JCB High Performance Hydraulic Fluid ISO 46 63 litres (14.1 UK gal) Brake System 1.2 litres (0.27 UK gal) JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System 406 Water/Anti-freeze (see Coolant mixture) ASTM D3306-74 12.5 litres (2.8 UK gal) 408 15.5 litres (3.5 UK gal) Fuel System 406 Diesel Oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D. 65 litres (14.5 UK gal) 408 90 litres (20.2 UK gal) Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system. 1 General 9803/4200 1 1 - 1 Issue 6

1 - 2 1 General 9803/4200 1 1 - 2 Issue 4 FLUIDS, CAPACITIES AND LUBRICANTS Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION Engine Oil -18 to 0° C 10.7 litres (2.4 UK gal) JCB Torque Converter Fluid API CD MIL-L-2104C -10 to 50° C JCB 15W/40 Multigrade Gearbox Syncro Shuttle †19 litres (4.2 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Powershift †13 litres (2.9 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Transfer box 1.3 litres (0.3 UK gal) JCB HD 90 Gear Oil API-GL-5, MIL-L-2105C Axles 407 5.0 litres (1.1 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B 409 16 litres (3.6 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B Hydraulic System Up to 38° C 63 litres (14.1 UK gal) JCB Special Hydraulic Fluid ISO 32 Above 38°C JCB High Performance Hydraulic Fluid ISO 46 Brake System 1.2 litres (0.27 UK gal) JCB Light Hydraulic Fluid ISO 15 CAUTION: DO NOT USE ORDINARY BRAKE FLUID Cooling System 15.5 litres (3.5 UK gal) Water/Anti-freeze (see Coolant mixture) ASTM D3306-74 Fuel System 90 litres (20.2 UK gal) Diesel Oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D. Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

1 - 3 1 General 9803/4200 1 1 - 3 Issue 2* FLUIDS, CAPACITIES AND LUBRICANTS Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run- in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended below. ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION Engine Oil -18 to 0° C 10.7 litres (2.4 UK gal) JCB Torque Converter Fluid API CD MIL-L-2104C -10 to 50° C JCB 15W/40 Multigrade Gearbox Syncro Shuttle †19 litres (4.2 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Powershift 13 litres (2.9 UK gal) JCB Special Transmission Fluid Ford ESN-M2C 33G Transfer box 1.3 litres (0.3 UK gal) JCB HD 90 Gear Oil API-GL-5, MIL-L-2105C Axles 16 litres (3.6 UK gal) JCB Special Gear Oil Ford ESE-M2C 86B Hydraulic System Up to 38° C 63 litres (14.1 UK gal) JCB Special Hydraulic Fluid ISO 32 Above 38°C JCB High Performance Hydraulic Fluid ISO 46 Cooling System 15.5 litres (3.5 UK gal) Water/Anti-freeze (see Coolant mixture) ASTM D3306-74 Fuel System 90 litres (20.2 UK gal) Diesel Oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D. Grease Points JCB Special MPL Grease Lithium based, No. 2 consistency Wear Pad Runways JCB Waxoyl Note: The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator. † The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

1 - 10 1 General 9803/4200 1 1 - 10 Issue 1 TORQUE SETTINGS Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size Hexagon (A/F) Torque Settings in (mm) in Nm kgf m lbf ft 1 /4 (6.3) 7 /16 14 1.4 10 5 /16 (7.9) 1 /2 28 2.8 20 3 /8 (9.5) 9 /16 49 5.0 36 7 /16 (11.1) 5 /8 78 8.0 58 1 /2 (12.7) 3 /4 117 12.0 87 9 /16 (14.3) 1 /16 170 17.3 125 5 /8 (15.9) 15 /16 238 24.3 175 3 /4 (19.0) 1 1 /8 407 41.5 300 7 /8 (22.2) 1 5 /16 650 66.3 480 1 (25.4) 1 1 /2 970 99.0 715 1 1 /4 (31.7) 1 7 /8 1940 198.0 1430 1 1 /2 (38.1) 2 1 /4 3390 345.0 2500 Metric Grade 8.8 Bolts Bolt Size Hexagon (A/F) Torque Settings (mm) mm Nm kgf m lbf ft M5 (5) 8 7 0.7 5 M6 (6) 10 12 1.2 9 M8 (8) 13 28 3.0 21 M10 (10) 17 56 5.7 42 M12 (12) 19 98 10 72 M16 (16) 24 244 25 180 M20 (20) 30 476 48 352 M24 (24) 36 822 84 607 M30 (30) 46 1633 166 1205 M36 (36) 55 2854 291 2105 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

2 - 1 1 General 9803/4200 1 2 - 1 Issue 5* A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the schedules are done to keep the machine in a safe and efficient working condition. A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the schedules are done to keep the machine in a safe and efficient working condition. The schedules are based on machine running hours. Keep a regular check on the hourmeter readings. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. First Pre-start Cold Checks Operation 10 50 100 500 1000 2000 Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr ENGINE Generally for Leaks - Check ❑ Oil level - Check ❑ ❑ Oil and Filter † - Change ❑ ❑ ❑ ❑ Fuel Filter - Drain ❑ Fuel Filter † - Change ❑ ❑ ❑ ❑ Coolant Level and Antifreeze Strength - Check ❑ ❑ ❑ ❑ ❑ Air Cleaner Dust Valve - Clean ❑ ❑ Air Cleaner Outer Element - Change ❑ ❑ Air Cleaner Inner Element - Change ❑ Coolant - Change ❑ Fuel Lift Pump - Clean ❑ ❑ ❑ ❑ Fuel Sedimenter - Drain ❑ ❑ Fan Belt Tension/Condition - Check ❑ ❑ ❑ ❑ ❑ Valve Clearances - Check and Adjust ❑ Engine Mount Security - Check ❑ ❑ ❑ ❑ Fuel System for Leaks and Contamination - Check ❑ ❑ ❑ ❑ ❑ TRANSMISSION AND AXLES Hub Oil Levels - Check ❑ Hub Oil †† - Change ❑ ❑ Oil Filter - Change ❑ ❑ ❑ ❑ Drive Axle(s) Oil Level - Check ❑ Drive Axle(s) Oil †† - Change ❑ ❑ Transmission Oil Level - Check ❑ ❑ Transmission Oil - Change ❑ ❑ Transmission Strainer - Clean ❑ ❑ Transfer Gearbox Oil Level - Check ❑ Transfer Gearbox Oil - Change ❑ ❑ ❑ Axle Breather(s) - Clean ❑ Drive shaft/Prop. Shaft Security - Check ❑ ❑ ❑ ❑ Drive Shaft/Prop. Shaft - Lubricate ❑ ❑ ❑ ❑ Axle Mount Security - Check ❑ Transmission Mount Security - Check ❑ HYDRAULICS Oil Filter - Change ❑ ❑ ❑ ❑ Oil - Sample/Change ❑ Suction Strainer - Clean ❑ Oil Level - Check ❑ ❑ ❑ ❑ Hoses - Damage or Leaks - Check ❑ ❑ ❑ ❑ ❑ Rams - Condition - Check ❑ ❑ ❑ ❑ Pipework - Damage or Leaks - Check ❑ ❑ ❑ ❑ ❑ *

2 - 2 BRAKES Parking Brake - Check and Adjust ❑ ❑ ❑ ❑ ❑ Brake System Fluid Level - Check ❑ ❑ ❑ ❑ Brake System Fluid - Change ❑ ELECTRICS Battery Electrolyte Level - Check ❑ ❑ ❑ ❑ Wiring for Chaffing - Check ❑ ❑ ❑ ❑ ❑ Battery Terminals for Condition and Tightness - Check ❑ ❑ ❑ ❑ ❑ BODY AND FRAMEWORK All Articulation and Steer Pivots - Grease ❑ ❑ All Loader Pivots - Grease ❑ ❑ All Pivot Pins - Check and Grease ❑ ❑ ❑ ❑ ❑ Windscreen Washer Fluid Level - Check ❑ ❑ ❑ ❑ ❑ ROPS/FOPS Structures - Check ❑ ❑ ❑ Boom Wear Pads * - Check and Inspect ❑ ATTACHMENTS Optional Equipment (as required) - Check ❑ ❑ ❑ ❑ First Functional Test Operation 10 50 100 500 1000 2000 and Final Inspection Hr Hr Hr Hr Hr Hr ENGINE Idle Speed - Check and Adjust ❑ ❑ ❑ ❑ Maximum Governed speed - Check and Adjust ❑ ❑ ❑ ❑ Torque Converter Stall Speed - Check ❑ ❑ ❑ ❑ Exhaust Smoke - Check ❑ ❑ Exhaust System Security - Check ❑ ❑ ❑ ❑ Air Inlet System Security - Check ❑ ❑ ❑ ❑ Coolant System for Leaks - Check ❑ ❑ Throttle System and Control Cable - Check ❑ ❑ Operation of Stop Control/E.S.O.S. - Check ❑ ❑ TRANSMISSION AND AXLES Torque Converter Mainline Pressure - Check ❑ ❑ ❑ ❑ Clutch Pack Pressures - Check ❑ ❑ ❑ ❑ Tyre pressure and condition - Check ❑ ❑ ❑ ❑ Wheel Nut Torque - Check ❑ ❑ ❑ ❑ Steering Operation - Check ❑ ❑ ❑ ❑ ❑ Neutral Start Operation - Check ❑ ❑ ❑ ❑ Forward/Reverse Selection/Operation - Check ❑ ❑ ❑ ❑ Gear Change and Selection - Check ❑ Clutch Disconnect - Check ❑ Reverse Alarm (if fitted) - Check ❑ Oil Cooler and Pipework - Check ❑ 1 General 9803/4200 1 2 - 2 Issue 5* First Pre-start Cold Checks Operation 10 50 100 500 1000 2000 Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr *

JCB 408 Wheel Loading Shovel Workshop Repair Service Manual

You're Reading a Preview

Recently Viewed