ASV RC-60 Track Loader Troubleshooting

The ASV Posi-Track RC60 compact track loader driveline system components: a 135 cu.in (2.2L) Perkins 404C-22T 4-cylinder indirect injection turbocharged diesel engine with a rated power of 60 hp (44.7 kW), and 1-speed hydro transmission. The hydraulic system has a pump with a rated flow of 17.4 gpm (65.9 lpm). The system pressure is 3000 psi (207 bar). The ASV RC-60 is equipped with radial-lift loader boom, axial-piston drive pumps, and 15" (380 mm) rubber tracks with embedded co-polymer cords. The loader has a max lift height of 115.5" (2920 mm) to hinge pin. The rated operating capacity is 1330 lbs (603 kg), and tipping load is 3800 lbs (1725 kg).

Engine Troubleshooting

Engine starts hard or won't start

Air in the fuel system - Air bleeding.
Fuel filter plugging - Clean or replace the filter.
Dirty or faulty injection nozzles - Replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Need to adjust valve clearance.
Faulty fuel injection pump - Replacement or repair required.

Diesel starts but immediately shuts off

Air cleaner is clogged - Clean or change.
Clogged fuel filter - Replace the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Faulty fuel injection pump - Repair or install a new fuel pump.

Engine stalls during operation

Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Fuel filter element clogging - Replace filter element.
Air trapped in fuel system - Bleed air.
Clogged injection nozzle - If necessary, replace with a new nozzle.
Wrong setting of fuel injection pump timing - Set it up as required.

Engine stalling at idle

Incorrectly set low idle speed - Adjust as required.
Fuel injection pump damage - Rebuild or install a new injection pump.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Valve out of adjustment - Adjustment procedure required.

Diesel engine is losing power

Clogged air cleaner - Clean or change.
Dirty or faulty injection nozzles - Test injection nozzles and change if necessary.
Uneven fuel injection pressure - Adjust to correct pressure.
Valve clearance is not correct - Adjust to proper valve clearance.
Wrong adjustment of low idle speed - Correct low idle settings.
Fuel lines or hoses clogging - Fuel hoses and lines must be clean.
Cylinder head gasket is worn - Replace cylinder head gasket.
Piston rings are worn or damaged - Replace the piston rings as required.

Engine overheats

Engine has a lack of coolant - Fill radiator to proper level and check components for faults.
Lack of engine oil - Check oil level and add oil as required.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or install new cap.
Loose or defective fan belt - Change as required.
Engine overload - Load reducing is recommended.

Low oil pressure

Engine oil insufficient - Fill crankcase to proper oil level.
Oil filter element clogged - Change or service engine oil filter.
Wrong oil viscosity - Use the specified type of engine oil.
Crankshaft bearing has incorrect oil clearance - Change bearings.
Defective oil pump - Inspect and change as required.

Engine knocking or noise

Low engine oil level - Check oil level and add oil as required.
Engine is cold - Warm up the engine.
Timing of fuel injection pump is incorrect - Adjust fuel injection pump as required.
Incorrectly set low idle speed - Adjust as required.
Defective fuel injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or defective - Need to change or align the connecting rod.
Broken or worn pistons - Replace the pistons.

Drive System Troubleshooting

Drive system won't work in one direction or either direction

Low hydraulic fluid level - Fill up the hydraulic fluid.
Undercarriage tracks are damaged or blocked - Repair or remedy blockage.
Relief valve is defective - Repair or replace relief valve.
Suction line or hydraulic filter is dirty - Change hydraulic filter or service suction line.
Faulty foot or hand controls - Repair or change.
Drive motor or pump is defective - Inspect and change as required.

Machine does not move straight or moves jerky

Undercarriage tracks are defective or jammed - Remove jamming or repair tracks.
Tracks are faulty or sagging - Replace tracks or adjust track sag with tension.
Track frame is clogged with debris, dirt, or foreign objects - Clean undercarriage track frame, remove foreign objects and debris.

Loss of power

Hydraulic oil filter is clogged - Replace hydraulic filter.
Defective or open relief valve - Close or change relief valve.
Worn or faulty transmission components - Inspect and change defective parts.
Damaged input drive shaft - Service or change faulty drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Drive system keeps overheating

Hydraulic fluid level low - Fill up the hydraulic fluid.
Hydraulic fluid filter is dirty - Change or clean hydraulic filter.
Relief valve is worn or damaged - Repair or change.
Drive pump or hydraulic motor malfunction - Replace or repair faulty component.
Hydraulic oil cooler is dirty - Cooling fins should be cleaned.
Transmission overloading - Load should be reduced.

Drive system is noisy

Oil viscosity is wrong - Use oil of proper viscosity.
Air in the hydraulic system - Bleed air from system.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Mechanical components of drive system are damaged or worn - Check the components for defect or damage and change if necessary.

Hydraulics Troubleshooting

Hydraulic system overheated

Hydraulic pressure is incorrect - Set pressure correctly.
Main relief valve improper adjustment or failure - Replace or set up the relief valve.
Hydraulic oil is dirty - The oil must be changed.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Lift arm can't drop or lift

Damaged lift controls - Inspect and repair if necessary.
Hydraulic pump failure - Install new pump or repair it.
Defective hydraulic control valve - Replace or repair the valve.
Hydraulic cylinder is defective - Repair or install a new lift cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Bucket does not function

Bucket tilt controls malfunction - Repair or replace.
Hydraulic pump failure - Repair or replace pump if necessary.
Hydraulic control valve is faulty - Repair or change the valve.
Damaged bucket cylinder - Repair or change cylinder.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.

Bucket or lift arm is working slowly

Defective hydraulic pump - Check hydraulic pump flow and replace pump if necessary.
Leaking hydraulic cylinder - Replace cylinder piston seals.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.
Defective or not adjusted hydraulic control valve - Adjust properly or repair.
Low hydraulic pressure - Hydraulic pressure must be set correctly.

Lift arm or bucket jerks when working

There is air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element clogging - Clean or change the filter.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Cylinder tube or rod is scored - Replace failed component.

Excessive hydraulic pump noise

Hydraulic leaks or lack of oil - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is dirty - Clean or install new filter.
Suction line is clogged - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Remove air from hydraulics.
Pump parts are damaged - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery does not charge

Corroded or loose electrical wire connections - Service or tighten cable connections.
Defective battery terminal clamps - Replace terminal clamps.
Bad cell in battery - Replace the battery.
Damaged or loose belt - Belt needs to be adjusted or changed.

Starter turning slow

Battery capacity is low - Battery needs to be recharged.
Battery runs out quickly - Service charging system or replace battery.
Battery terminals are corroded or wires are disconnected - Check wiring connections and replace or clean terminals.

Starter motor won't turn

Battery is drained or worn - Battery needs to be recharged or replaced.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery output - Battery needs to be recharged.
Starter motor failure - Repair or replace starter.