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Home / Wheel Loaders / JCB Wheel Loaders / JCB 409

JCB 409 Troubleshooting

The JCB 409 wheel loader is powered by Kohler KDI 2504 TCR four-cycle four-cylinder turbocharged diesel engine with a rated power of 74 hp (54.5 kW) at 2200 rpm. The JCB 409 is equipped with a 2-speed or 3-speed hydrostatic transmission, power steering system, hydraulic wet disc brakes, and 16.0/70x20 standard tires. The hydraulic system has a pump with fluid flow rate of 22 gpm (83.2 lpm) or 30 gpm (113.7 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 4950 lbs (2250 kg) and tipping load of 9900 lbs (4500 kg). The max lift height is 131.5" (3340 mm) to hinge pin, and breakout force is 10450 lbs (4750 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is clogged - Change filter element.
Fuel injection nozzles are faulty or clogged - Check and replace nozzles if required.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Adjust valve clearance.
Defective fuel injection pump - Replace injection pump or repair it.

Engine starts but stalls immediately
Dirty air cleaner - Clean or change cleaner.
Dirty fuel filter - Service or replace the filter.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Fuel injection pump failure - Change pump or rebuild it.

Diesel shuts off while driving
Coolant temperature is low - Normalize the temperature by warming up the engine.
Clogged fuel filter - Clean or change the filter.
Air in the fuel system - Air bleeding.
Fuel injection nozzles are faulty or clogged - Clean or change injection nozzles.
Wrong setting of fuel injection pump timing - Set up as recommended.

Engine stalls while idling
Low idle speed set incorrectly - Correct low idle adjustment.
Fuel injection pump is defective - Replace or rebuild injection pump.
Fuel injector fault - Replace or clean fuel injectors.
Valve clearance is out of adjustment - Check and adjust as required.

Diesel engine is losing power
Air cleaner is dirty - Clean or replace air cleaner element.
Fuel injection nozzles are clogged or faulty - Service or change injection nozzles.
Fuel injection pressure is incorrect - Adjust to proper pressure.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Low idle speed adjustment is incorrect - Adjustment required.
Fuel hoses or lines clogging - Clean fuel system hoses and lines.
Defective cylinder head gasket - Replace cylinder head gasket.
Defective or worn piston rings - Piston rings need to be replaced.

Engine is overheated
Coolant level is low - Add coolant and check the components of cooling system.
Not enough engine oil - Fill the crankcase with engine oil.
Defective radiator cap or clogged radiator fins - Clean radiator or change cap.
Excessive wear of the fan belt - The fan belt needs to be replaced.
Engine is under excessive load - Load reducing required.

Oil pressure too low
Oil level is insufficient - Checking oil level and add if necessary.
Clogged oil filter element - Service or change engine oil filter element.
Improper type of engine oil - Use the specified type of engine oil.
Incorrect oil clearance in crankshaft bearing - Install new bearings.
Oil pump is damaged - Repair or replace.

Engine knocking or noise
Engine oil insufficient - Fill up the oil to required level.
Low coolant temperature - Normalize the temperature by warming up the engine.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Too low idle RPM - Adjust low idling as recommended.
Clogged or defective injectors - Replace fuel injectors.
Faulty or misaligned connecting rod - Connecting rod needs to be replaced or aligned.
Pistons are broken or worn - Install new pistons.

Hydrostatic Transmission Troubleshooting

Excessive hydrostatic transmission noise
Low transmission oil level or contaminated oil - Fill to required level or change the transmission oil.
Worn or unadjusted speed control linkage - Adjust or replace linkage.
Relief valve is stuck - Replace valve as required.
Transmission is under excessive load - Reduce loading.
Damaged or worn components of hydrostatic transmission - After disassembly and inspection, replace defective components.

Loss of power
Transmission fluid level is low - Check and refill the transmission fluid.
Relief valve is damaged - Change the valve.
Bent or unadjusted speed control pedal linkage - Adjust or repair linkage.

Transmission fluid over heats
Transmission fluid insufficient - Checking transmission fluid level and add if necessary.
Plugged transmission oil filter - Clean or replace the transmission filter.
Damaged or clogged cooling components - Check all cooling components and clean or replace if required.
Excessive loading - Reduce the load is required.

Transmission oil leaking
Damaged gaskets or seals - Install new components.
Internal transmission housing pressure is too high - Replace worn components.
Oil drain line is clogged - Clean or change the line.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure is incorrect - Adjust pressure correctly.
Unadjusted or defective main relief valve - Adjust or replace the relief valve.
Hydraulic oil contamination - Hydraulic oil change required.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Worn hydraulic oil pump - Repair or change pump if required.

Lift arm does not lower or raise
Lift controls malfunction - Repair or change.
Hydraulic pump is broken - Install new pump or repair it.
Hydraulic control valve is faulty - Install a new valve or repair it.
Hydraulic cylinder is broken - Repair or change hydraulic cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.

Bucket does not tilt
Bucket controls are faulty - Inspect and repair if necessary.
Defective hydraulic pump - Install new pump or repair it.
Hydraulic control valve malfunction - Repair or change hydraulic valve.
Hydraulic bucket cylinder not working - Repair or install a new cylinder.
Hydraulic oil is insufficient - Need to add oil.

Slow bucket or lift arm operation
Defective hydraulic pump - Test pump flow rate and replace pump if required.
Leaking hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is unadjusted or worn - Repair or set properly.
Low hydraulic pressure - Adjust pressure as required.

Lift arm or bucket is moving jerkily
Air in the hydraulic system - Need to bleed air.
Hydraulic oil filter is clogged - Change or clean oil filter.
Dirty hydraulic oil - The oil must be changed.
Cylinder tube or rod scoring - Change damaged component.

Excessive hydraulic pump noise
Not enough oil or hydraulic system leaking - Refill hydraulic oil or repair leaks in system.
Clogged hydraulic filter - Change or clean oil filter.
Clogged suction line - Clean suction line as required.
Air trapped in hydraulic pump - Air bleeding is required.
Worn pump components - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery does not charge
Corroded or loose cable connections - Tighten or clean electrical wiring connections.
Electrical terminal connectors are defective - Install new terminal connectors.
Dead cell in battery - Battery change required.
Damaged or loose belt - Install a new belt or adjust belt tension.

Starter motor turns slow
Low battery capacity - Low battery charging, charge as required.
Battery will not hold charge - Service or change the battery.
Bad terminals or disconnected battery cables - Check cable connections and replace or service terminals.

Starter will not crank
Battery is drained or defective - Replace or charge as required.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery capacity - Low battery charging, charge as required.
Damaged starter motor - Repair or install a new starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders