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Troubleshooting
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Engine
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Hydraulic & final drive
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Electrical
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Controls
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Q: |
I have difficulties starting my engine in my loader, what could be the cause? |
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A: |
Here are a few things you can check:
Low cranking speed - Check the charge in the battery. Check starter. Repair or replace
Incorrect pump timing - Check the pump timing
Restricted fuel filter - Check and flush or replace the fuel filter clear.
Contaminated fuel - Check for water in the fuel
Low compression - Check the engine compression
Air in system - Check for air leaks on the suction side of the system
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
I have fuel mixed into my lubricant oil, why? |
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Here are a few possible explanations to this:
Injection pumps plunger worn - Replace pump element or pump
Injection pump broken - Replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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I have high oil pressure, what causes this? |
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Here are a few possible explanations to this:
Relief valve defective Replace
Engine oil insufficient - Replenish
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
I have low oil pressure, what causes this? |
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Here are a few possible explanations to this:
Engine oil insufficient Replenish
Oil strainer clogged Clean
Relief valve stuck with dirt Clean
Relief valve spring weakened or broken Replace
Excessive oil clearance of crankshaft bearing Replace
Excessive oil clearance of crank pin bearing Replace
Excessive oil clearance of rocker arm bearing Replace
Oil passage clogged Clean
Oil pump defective Replace
Different type of oil - Use the specified oil type
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
I have water mixed into my lubricant oil, why? |
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Here are a few possible explanations to this:
Head gasket defective Replace
Cylinder block or cylinder head flawed - Replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My battery quickly discharges, what can cause this? |
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Here are a few possible explanations to this:
Battery electrolyte insufficient - Replenish distilled water
Fan belt slips - Adjust belt tension or change
Wiring disconnected Connect
Rectifier defective - Test, replace
Alternator defective - Test, repair, replace
Battery defective - Test, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My engine does not develop full power, what could be the cause of this? |
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Here are a few possible explanations to this:
Unsuitable fuel used - Use the specified fuel
Clogged air cleaner - Clean, replace
Fuel line, filter obstruction - Test, repair, replace
Incorrect injection timing Adjust
Engines moving parts seem to be seizing - Repair or replace
Uneven fuel injection - Repair or replace injection pump
Deficient nozzle injection - Repair or replace nozzle
Compression leak - Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My engine keeps overheating, why? |
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Here are a few possible explanations to this:
Fan belt broken or elongated - Change or adjust
Cooling water insufficient - Check for leaks, replenish
Radiator net and radiator fin clogged with dust Clean
Inside of radiator corroded - Clean or replace
Cooling water flow route corroded - Clean or replace
Radiator cap defective Replace
Overload running - Loosen the load
Head gasket defective Replace
Restricted exhaust - Check
Incorrect injection timing Adjust
Water pump failure - Test, repair, replace
Thermostat failure - Test, replace
Low on engine oil - Check, replenish if necessary
Collapsed hose - Replace
NOTE: Refer to repair manual for specifications, testing, removal and installation |
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Q: |
My engine revolution is not smooth, what should I look for? |
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A: |
Here are a few things you can check:
Fuel filter clogged or dirty - Clean or change
Air cleaner clogged - Clean or change
Fuel leak due to loose injection pipe retaining nut - Tighten nut
Injection pump malfunctioning - Repair or replace
Incorrect nozzle opening pressure Adjust
Injection nozzle stuck or clogged - Repair or replace
Fuel overflow pipe clogged Clean
Governor malfunctioning - Repair
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My engine revolution is not smooth, what should I look for? |
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Here are a few things you can check:
Fuel filter clogged or dirty - Clean or change
Air cleaner clogged - Clean or change
Fuel leak due to loose injection pipe retaining nut - Tighten nut
Injection pump malfunctioning - Repair or replace
Incorrect nozzle opening pressure Adjust
Injection nozzle stuck or clogged - Repair or replace
Fuel overflow pipe clogged Clean
Governor malfunctioning - Repair
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My engine starts and stops, what could be the cause? |
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Here are a few things you can check:
Fuel starvation - Check and flush clean restricted fuel lines or fuel filter
Contaminated fuel - Check for water in the fuel
Restricted air intake - Check for restrictions in the air intake
Engine overheating - Check cooling system
Air in system - Check for air leaks on the suction side of the system
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My engine will not start, what should I check for? |
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Here are a few things you can check:
Low fuel - Replenish fuel
Air in the fuel - Vent air
Water in the fuel - Change fuel and repair or replace the system
Fuel pipe clogged Clean
Fuel filter clogged - Clean or change
Air filter dirty - Clean or replace
Excessively high viscosity of fuel or engine oil at low temperature - Use the specified fuel or engine oil
Fuel with low octane number - Use the specified fuel
Fuel leak due to loose injection pipe retaining nut - Tighten nut
Incorrect injection timing Adjust
Fuel cam shaft worn - Replace
Injection nozzle clogged Clean
Injection pump malfunctioning - Repair or replace
Seizure of crankshaft, camshaft, piston, cylinder liner or bearing - Repair or replace
Compression leak from cylinder - Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder
Improper valve timing - Correct or replace timing gear
Piston ring and liner worn Replace
Excessive valve clearance Adjust
Faulty starter switch - Test, repair or replace.
Low or weak battery - Charge, test, replace.
Irregular or faulty fuel supply - Test fuel pump. Repair or replace
Glow plugs not heating - Test, repair, replace
Starter malfunctioning - Repair or replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My loader uses excessive lubricant oil, what causes this? |
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Here are a few possible explanations to this:
Piston rings gap facing the same direction - Shift gap direction
Oil ring worn or stuck Replace
Piston ring groove worn Replace
Valve stem and guide worn Replace
Crankshaft bearing and crank pin bearing worn Replace
Engine oil level too high - Drain to proper level
Leaking cylinder head gasket Replace
Clogged return hole of oil ring - Inspect, repair, replace
External oil leak - Repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My starter does not turn over, what could be the problem? |
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Here are a few things you can check:
Battery discharged - Charge, test, replace.
Key switch malfunctioning - Test, replace
Wiring disconnected - Connect
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
The exhaust coming out of my loader is either white or blue, what might be the cause? |
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Here are a few possible explanations to this:
Excessive engine oil - Reduce to the specified level
Low grade fuel used - Used the specified fuel
Fuel filter clogged Change
Air cleaner clogged - Clean or change.
Excessive angle operation - Work on more level ground or do not stay on an angle for long lengths of time
Inoperative or no thermostat - Test, replace
Coolant in cylinders - Test, repair
Low cylinder compression - Test, repair
Worn or scored piston or rings - Repair, replace
Valve guides worn - Repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
I have no drive on one side, what should I look for? |
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Here are several things you should check:
Drive chain failure - Inspect the drive chain and connecting link. Replace any damaged parts.
Drive motor sprocket failure - Inspect the drive sprocket and splines. Replace parts as required.
Drive motor or hydrostatic system failure - Refer to the hydrostatic drive section. Diagnose and make repairs as required.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
I have no hydraulic power (there is no flow from the gear pump). What Should I do? |
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Here are a few things you should check:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Adapter kit between engine and tandem pump failure - Inspect and replace the damaged parts as required. Check for proper alignment.
Gear pump not functioning - Inspect, test and replace damaged parts if needed.
Splined coupling failure in the hydrostatic pump - Inspect coupling for sheared splines. Also check pump shaft bearings.
NOTE: Refer to repair manual for specifications, testing, removal and installation. |
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Q: |
I have no hydraulic power, but I have full flow from gear pump. What Should I do? |
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A: |
Here are a few things you should check:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Control linkage disconnected or binding - Inspect, adjust or replace parts.
Auxiliary hydraulics engaged - Disengage the switch.
Relief valve failure or out of adjustment - Check pressure. Adjust or repair as required.
NOTE: Refer to repair manual for specifications, testing, removal and installation. |
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Q: |
My final drive is noisy, what could be causing that? |
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There are several possible causes for the noise:
No lubricating oil - Check oil level. Add recommended oil to correct level.
Axle has too much end play. (Bearing pre-load) - Check and adjust the bearing pre-load on the axle bearing.
NOTE: Refer to repair manual for specifications, testing, removal and installation. |
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Q: |
My hydraulic cylinders will not support a load, they "leak" down, what causes this? |
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There could be several causes for this:
Control valve spools not centering - Check control linkage and control valve spool spring centering devise.
Cylinder seal(s) failure - Visually check for leakage, test if necessary.
Load check valve not functioning - Inspect, test and replace damaged parts if needed.
External leak between control valve and cylinders - Inspect and repair.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
My wheel studs keep shearing off, why is this happening and what can I do to prevent this from happening? |
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You should check the wheel nuts to see if they are loose, and if so, replace the wheel studs. We recommend you check wheel nut torque daily. Torque wheel nuts to specification.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
What can cause the hydraulic oil to overheat? |
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There are several possible reasons for this:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Oil cooler plugged or dirty - Clean the cooling fins.
Auxiliary hydraulics engaged - Disengage.
Cooling fan damaged or inoperative - Check fan for any breakage and ensure the drive belt is at the right tension.
Engine rpm too low - Check engine RPM and adjust if needed.
Temperature sender defective - Test and replace if necessary.
Relief valve failure or out of adjustment - Check pressure, adjust or replace.
Wrong type of hydraulic fluid - Replace with recommended oil.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
What causes lubrication oil leaking through the filler breather cap? |
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There are several possible reasons for this:
Lubricating oil level too high - Check the oil level and drain to proper level if necessary.
Drive motor shaft seal leakage - Inspect and repair damaged parts.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
Why do my wheel studs keep stripping? |
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The wheel studs keep stripping because the wheel nuts may be over tightened. In order to fix this, replace the wheel studs. Check wheel nut torque daily. Torque wheel nuts to specification.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
Why does my boom rise slowly at full rpm? |
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There are several possible explanations for this:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Control linkages loose or worn - Inspect, adjust or replace parts.
Auxiliary hydraulics engaged - Disengage the switch.
Lifting more than rated capacity - Reduce the load.
Engine rpm too low - Check engine rpm and reset.
Relief valve failure or out of adjustment - Check pressure. Adjust or repair as required.
Cylinder seal(s) failure - Visually check for leakage, test if necessary.
Internal leakage in the control valve - Inspect and do pressure test on the control valve and repair as required
Limiter on control cross shaft misadjusted
Inspect, adjust or replace worn parts.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
Why does my hydraulic drive act erratically? |
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There are a few possibilities for this:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Control linkages loose or worn - Inspect, adjust or replace parts.
Air in hydraulic system - Check for leaks between the oil reservoir and pump.
Load check valve not functioning - Test, inspect and replace damaged parts.
Control valve spool spring return mechanism not functioning - Inspect and replace damaged parts if needed.
NOTE: Refer to repair manual for specifications, testing, removal and installation.
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Q: |
My boom controls seem to be stiff, what can I do to loosen it? |
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Here are a few things you can try:
Cable wear Replace
Pivot wear - Replace parts
Control valve wear - Test, repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My brake will not hold, what can cause this? |
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Here are a few possible reasons for this:
Service plunger on brake valve open - Inspect and service
Brake disc wear or damage - Repair, replace
Cable could be broken or stretched - Test, repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
The aux (electric) is not functioning. What should I do? |
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1. First determine if there is power going to the coils on the valve. To do this, with the ignition turned to the "RUN" position (do not start), and the wires unplugged from the auxiliary coils on the valve, test with a test light to see if you have power going to them when you rock the switch on the handle. When you push the switch on one side you should have power going to one coil, and when the switch is pushed to the other side you should have power going to the other coil. If no power is going to the coil proceed to step 2.
2. The next step would be to check the fuse in the fuse box. This is a 10 amp fuse (brown wire with yellow tracer). If the fuse is good proceed to step 3.
3. The next thing to check would be your switch in the handle. To check this you will need to; make sure the machine is turned off, remove the seat, unplug the wires that come out of the bottom of the control lever on the LH side. Next connect the negative from an ohm meter to the green wire and test the rocker switch with by pressing one side of the switch and seeing if there is continuity one of the other wires. Do the same for the other side of the switch. If the switch is good, then there is a short in your harness. Trace out and fix short or broken wire. If the switch is faulty, replace with a new one.
4. If you have power going back to your solenoids on your valve but the auxiliary hydraulics still won't work, check the coils for resistance to see if they are within spec. They should have 3 to 5 ohms resistance. If they do not fall within this spec then it is faulty and need replacing.
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Q: |
When I turn my key, I have no power. |
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1. First, make sure you have a fully charged battery. This can be done by testing it with a volt meter. You should have around 12 volts.
2. Next, check to see if you have power at your starter. Using a test light connect the clip end of the test light on a good clean ground on the frame or engine surface and use the point end to test the stud or bolt on the engine starter where the positive cable connects.
3. Next you will need to confirm that you have power going through the starter and solenoid. With the test light, check the starter where the ignition wire connects on. The ignition wire is usually white.
4. If you have power coming out of the solenoid, you will have to repeat this procedure for each of the following connections until you reach the dash panel.
5. Next you will have to test the ignition switch for power. To do this you will have to remove the dash panel to expose the back of the ignition switch. Using the test light, check to see if you have power coming into the switch through the white wire (Terminal 30). If you do, then proceed to step f.
6. Next, turn the ignition to the run position. With the test light, check to see if you have power coming to the black with white tracer wire (terminal ACC). If you do than proceed to step g.
7. Making sure the wires on the ignition switch do not ground out, leave the ignition turned to the run position and locate and open the fuse panel located in the engine compartment of the machine. Using the test light, test to see if there is power coming into the fuse panel buy testing the main screw. Then test both sides of each fuse for power and where each wire connects.
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Q: |
My auxiliary is inoperative (solenoid control type), what can I do? |
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Here are a few things you can try:
Blown fuse - Test, replace
Switch (s) failure - Test, replace
Aux. valve malfunction - Test, repair, replace
Electrical short - Test, repair, replace
Bad electrical ground - Test, repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My boom controls are inoperative, what can cause this to happen? |
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Here are a few possible explanations for your problem:
Damaged cables, linkage Replace
Safety switch(s) - Adjust, replace
Bad electrical ground Repair
Blown fuse Replace
Valve lock malfunction - Replace parts
Low hydraulic oil Replenish
No oil pressure - Make repairs
NOTE: Refer to repair manual for specifications, testing, removal and installation |
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Q: |
My boom operation is slow, what can I do to correct this? |
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Here are a few things you can check:
Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
Cable linkage binding - Replace, adjust
Aux. hydraulics engaged Disengage
Engine RPM low Adjust
Control valve relief - Check pressure, replace if necessary.
Cylinder seal, damage - Test, repair or replace
Anti-cavitation check valve spring broken - Replace.
Internal leak in pump due to wear - Check pump flow and repair or replace as necessary.
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My loader creeps and will not center, what causes this and how can I fix it? |
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Here are a few things you can do:
Neutral detent out of adjustment - Adjust as needed.
Worn, loose linkage - Replace, tighten parts
Binding of spring bushing in spring box - Align spring box with linkage.
Control levers binding or rubbing with safety shields or insulation - Adjust.
Control lever bearings binding in lever assembly - Inspect, replace or clean as required.
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
My loader is not tracking straight, what should I look for? |
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Here are a few things you can check:
Limiter stops need adjustment Adjust
Binding linkage - Repair, replace
Hydrostatic failure - Repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
The brakes on my loader wont release. What can I do to fix this? |
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Here are a few things you can try:
Blown fuse Replace
Safety switch malfunction - Adjust, replace
Lack of hydrostatic charge pressure, test, repair
Brake valve failure - Repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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Q: |
What causes the steering to be "jerky" or "jumpy"? |
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Here are a few things you can check:
Worn, loose linkage Replace
Binding linkage - Repair, replace
Linkage adjustment Adjust
Low charge pressure - Repair, replace
NOTE: Refer to repair manual for specifications, testing, removal and installation
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