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

JCB 406 (2504M Tier 3), 407, 409 (2504TCR Tier 4) KOHLER Engine Operator Manual 9821-9350 - Image 2

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

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

JCB 406 (2504M Tier 3), 407, 409 (2504TCR Tier 4) KOHLER Engine Operator Manual 9821-9350 - Image 5

jcb 406 2504m tier 3 407 409 2504tcr tier 4 kohler engine operator manual 9821 9350 2

jcb 406 2504m tier 3 407 409 2504tcr tier 4 kohler engine operator manual 9821 9350 3

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

$20.00

Type Of Manual: Operator Manual
ManualID: 9821-9350
Number of Pages: 228
Size: 37.0MB
Format: PDF

Category: JCB Operator Manual PDF

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 ………………..

Rate this product