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Home / Wheel Loaders / JCB Wheel Loaders / JCB 407 ZX |
JCB 407 ZX Troubleshooting
The
JCB 407 ZX wheel loader driveline system components: a 269 cu.in (4.4L) Perkins
1104C-44 4-cylinder direct injection liquid-cooled diesel engine with a rated
power of 67 hp (50.3 kW), and 2-range or 3-range hydrostatic transmission. The
hydraulic system has a pump with a rated capacity of 17.4 gal/min (66 l/min).
The system relief pressure is 3190 psi (220 bar). The JCB 407 ZX is equipped
with a power steering, hydraulic wet disc brakes, and 12.5x18 tires. The wheel
loader has a maximum lift height of 122" (3100 mm) and breakout force of 10340
lbs (4700 kg). The rated operating capacity is 3405 lbs (1545 kg), and tipping
load is 6810 lbs (3090 kg).
Engine Troubleshooting |
Engine starts up hard or will not start
There is air in the fuel system - Bleed the system.
Fuel filter plugged - Clean or replace the filter.
Fuel injection nozzles are damaged or dirty - Service or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Incorrect valve clearance - Adjust to proper valve clearance.
Fuel injection pump is not operating properly - Change pump or rebuild it.
Engine starts but stalls suddenly
Plugged air cleaner - Clean or replace element.
Fuel filter element clogging - Replace filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Replace fuel injectors.
Fuel injection pump is defective - Replace injection pump or repair it.
Engine stalls after running
Engine is not fully warmed up - Warm up to required temperature.
Fuel filter plugging - Clean the filter or install new filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Fuel injection nozzles are damaged or dirty - Service or change injection nozzles.
Incorrect adjustment of fuel injection pump timing - Check the fuel injection pump timing adjustment.
Engine stops when idle
Incorrectly set low idle speed - Adjust low idling as recommended.
Fuel injection pump malfunctioning - Rebuild or replace pump.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Valve clearance is wrong - Correct valve clearance needs to be set.
Engine power is insufficient
Clogged air filter - Replace or clean air filter element.
Defective injection nozzle - Check and replace nozzles if required.
Fuel injection pressure is wrong - Adjust to correct pressure.
Valve clearance is wrong - Have it adjusted.
Incorrectly set low idle speed - Adjust low idling as recommended.
Fuel lines or hoses are dirty - Clean fuel lines and hoses.
Leaking cylinder head gasket - Cylinder-head gasket replacement required.
Damaged or leaking piston rings - Replace piston rings.
Engine overheated
Engine coolant is insufficient - Top up coolant fluid and check system for leaks.
Engine oil level is low - Add oil to the engine crankcase.
Clogged radiator core or damaged radiator cap - Clean radiator or replace cap.
Broken or loose fan belt - Belt change is required.
Diesel engine overloaded - Load reducing is recommended.
Oil pressure too low
Low oil level - Check oil level and add oil as required.
Dirty oil filter element - Change or service engine oil filter.
Oil grade or viscosity is incorrect - Fill up with the proper oil viscosity.
Excessive main bearing oil clearance - Bearings need to be reinstalled.
Worn oil pump - Check and replace if necessary.
Engine knocking sound or abnormal noise
Engine oil level is low - Fill up the engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Fuel injection pump timing is wrong - Adjust according to specifications.
Incorrectly set low idle speed - Test and adjust.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Connecting rod is misaligned or worn - Connecting rod needs to be aligned or changed.
Pistons are scored or worn - Replace the pistons.
Hydrostatic Transmission Troubleshooting |
HST transmission noises
Contaminated transmission fluid or low fluid level - Pour fresh fluid or add transmission fluid to proper level.
Speed control pedal linkage is bent or not adjusted - Repair or adjust linkage.
Stuck relief valve - Replace the valve.
Transmission overloaded - The load should be reduced.
Worn or defective transmission components - Check hydrostatic transmission components for defect or damage and change if necessary.
Power is too low
Transmission fluid insufficient - Add fluid to the transmission housing.
Relief valve malfunction - Install a new relief valve.
Defective or not adjusted speed control pedal linkage - Repair or adjust linkage.
Transmission fluid overheated
Transmission fluid level is low - Need to add transmission fluid.
Clogged transmission fluid filter - Service or change transmission fluid filter.
Cooling components are clogged or damaged - Check all cooling components and change or clean if required.
Excessive transmission load - Reduce loading.
Transmission oil leaks
Damaged seals or gaskets - Replace worn seal or gaskets.
High internal transmission case pressure - Change defective components.
Oil drain pipe is plugged - Check pipe and service if necessary.
Hydraulics Troubleshooting |
Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Main relief valve is faulty or misadjusted - Adjust relief valve or change if required.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Hydraulic oil level is insufficient - Check oil level and add hydraulic oil as required.
Worn hydraulic oil pump - Repair or install new hydraulic pump.
Boom cannot be lowered or raised
Lift controls are defective - Check and repair as required.
Defective hydraulic pump - Repair or change pump if required.
Faulty hydraulic control valve - Repair or change hydraulic valve.
Defective hydraulic cylinder - Repair or change hydraulic cylinder.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Bucket tilt does not work
Defective bucket controls - Repair or change.
Damaged hydraulic oil pump - Install new pump or repair it.
Hydraulic control valve is faulty - Install a new valve or repair it.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Boom or bucket is working slowly
Hydraulic pump is faulty - Check pump flow and change pump if necessary.
Hydraulic cylinder oil leakage - Change cylinder piston seals.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Defective or not adjusted hydraulic control valve - Adjust properly or repair.
Hydraulic pressure is low - Correct setting is required.
Jerky operation of the bucket or boom
There is air in the hydraulic system - Bleed air from system.
Hydraulic oil filter is dirty - Service or change the hydraulic filter.
Dirty hydraulic fluid - Hydraulic fluid change required.
Scored cylinder tube or rod - Change defective component.
Hydraulic pump makes excessive noise
Hydraulic leakage or lack of oil - Repair hydraulic leaks or add oil as required.
Dirty hydraulic filter - Replace or clean the filter.
Clogged suction line - Suction line must be serviced.
Pump sucks air - Air bleeding is required.
Damaged pump components - Install new hydraulic pump or rebuild it.
Electrical Troubleshooting |
Battery will not charge
Loose or corroded cable connections - Service or tighten cable connections.
Faulty battery terminal connectors - Change terminal connectors.
Faulty cell in battery - Change the battery.
Belt is worn or loose - Change belt or adjust belt tension.
Starter turning slow
Battery voltage is low - Charge the battery.
Battery is not holding charge - Battery needs service or replacement.
Disconnected cables or faulty battery terminals - Check battery wires and service or replace terminals.
Starter is not cranking
Battery is drained or defective - Need to charge or replace the battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery capacity is low - Battery is drained, charge it.
Starter motor is defective - Repair or replace starter.
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