ASV RS-75 Skid Steer Troubleshooting

The ASV RS-75 skid steer loader is powered by 177 cu.in (2.9L) Deutz TD2.9L4 vertical four-cylinder turbocharged diesel engine with a rated power of 74 hp (55 kW) at 2800 rpm. The ASV RS75 is equipped with a two-speed hydrostatic transmission, 100 ANSI continuous roller chains, and 12x16.5 standard tires. The hydraulic system has a gear pump with fluid flow rate of 22 gpm (83.2 lpm) or 30.9 gpm (117 lpm). The hydraulic pressure is 3335 psi (230 bar). The skid steer loader has a rated operating capacity of 2600 lbs (1180 kg) and tipping load of 5200 lbs (2360 kg). The lift height is 125 inches (3175 mm) to hinge pin, and dump height is 100 inches (2540 mm).

Engine Troubleshooting

Engine hard to start or will not start

Air in the fuel lines - Bleed the fuel lines.
Fuel filter plugged - Service the filter.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Have it adjusted.
Fuel injection pump malfunctioning - Replace injection pump or repair it.

Engine starts and then shuts off

Dirty air filter - Clean or change filter.
Fuel filter element is clogged - Clean or change the filter.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Fuel injection pump malfunction - Rebuild or change fuel pump.

Engine shuts off suddenly during operation

Coolant temperature is low - Engine is not warmed up to the required temperature.
Fuel filter is plugged - Replace filter element.
Air in fuel system - Bleed fuel system.
Clogged or burnt injection nozzle - Replace injection nozzles.
Wrong setting of fuel injection pump timing - Adjust as recommended.

Engine shuts off while idling

Low idle speed set incorrectly - Adjust low idle speed.
Fuel injection pump malfunctioning - Rebuild or change fuel pump.
Clogged or defective injectors - Test and replace fuel injectors if necessary.
Valve clearance is not correct - Check and adjust as required.

Low engine power

Plugged air cleaner - Service or replace air cleaner.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Insufficient fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Incorrect low idle setting - Need to adjust idle speed.
Fuel lines or hoses are dirty - Service fuel hoses and lines.
Worn cylinder head gasket - Install new cylinder head gasket.
Leaking or defective piston rings - Replace piston rings.

Engine overheating

Low engine coolant - Add coolant fluid and inspect the cooling system for leaks.
Insufficient engine oil - Check and refill engine oil.
Clogged radiator core or damaged radiator cap - Clean radiator or change cap.
Loose or damaged fan belt - Fan belt must be replaced.
Diesel engine is overloaded - Load reducing required.

Oil pressure is insufficient

Low oil level - Add oil as required.
Oil filter is dirty - Change or clean engine oil filter element.
Wrong oil viscosity - Use oil of correct viscosity.
Excessive oil clearance of crankshaft bearing - Bearing replacement required.
Oil pump is damaged - Replace as required.

Engine noises or knocks

Engine oil level is insufficient - Fill up the engine oil.
Engine is cold - Engine is not warmed up to the required temperature.
Timing of fuel injection pump is incorrect - Use the correct fuel injection pump timing adjustment.
Wrong adjustment of low idle speed - Adjustment required.
Damaged or clogged injectors - Clean fuel injectors or change it.
Connecting rod is misaligned or worn - Alignment procedure or replacement is required.
Pistons are broken or worn - Pistons need to be replaced.

Drive System Troubleshooting

Machine will not move in either direction or one direction

Hydraulic oil level is low - Fill the system to proper hydraulic oil level.
Faulty drive chain - Check drive chain and change faulty components.
Input drive shaft is defective - Service or change drive shaft.
Stuck relief valve - Repair or install a new relief valve.
Suction line or hydraulic filter is clogged - Replace hydraulic filter or clean suction line.
Hand or foot controls failure - Repair or change.
Worn drive motor or pump - Check and repair if required.

Reduced power

Plugged hydraulic oil filter - Replace or clean hydraulic filter.
Relief valve is defective or open - Close or change relief valve.
Faulty or damaged transmission components - Check and replace defective components.
Defective input drive shaft - Replace drive shaft.
Air trapped in hydraulic system - Bleed air from hydraulic system.

Drive system overheating

Low hydraulic fluid level - Fill up the hydraulic fluid.
Dirty hydraulic fluid filter - Change hydraulic filter.
Stuck relief valve - Repair or replace.
Drive pump or hydraulic motor malfunction - Check and repair if required.
Hydraulic oil cooler is plugged - Cooling fins need to be cleaned.
Drive system overload - Reduce loading.

Drive system is excessively noisy

Incorrect oil viscosity - Drain and refill with correct oil.
Air in the hydraulic system - Bleed air from hydraulic system.
Damaged drive pump or hydraulic motor - Repair or change faulty component.
Mechanical parts of drive system are damaged or worn - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system is overheated

Hydraulic pressure is not correct - Adjust it correctly.
Misadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Contaminated hydraulic fluid - Change hydraulic fluid.
Hydraulic fluid level is low - Add fluid to the hydraulic system.
Hydraulic pump is worn - Repair or replace pump if necessary.

Boom does not raise or lower

Lift controls malfunction - Inspect and repair if necessary.
Hydraulic pump is broken - Install new pump or repair it.
Hydraulic control valve malfunction - Repair or replace hydraulic valve.
Hydraulic cylinder failure - Repair or change hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket does not function

Bucket controls failure - Change or repair.
Hydraulic pump failure - Install new pump or repair it.
Faulty hydraulic control valve - Repair or replace the valve.
Hydraulic bucket cylinder not working - Change or repair cylinder.
Hydraulic oil level low - Need to add oil.

Slow boom or bucket action

Worn hydraulic oil pump - Test pump performance and replace pump if necessary.
Oil leaks from hydraulic cylinder - Cylinder seals need to be replaced.
Low hydraulic fluid level - Add fluid as required.
Hydraulic control valve is defective or set improper - Repair or adjust properly.
Hydraulic pressure has dropped - Set pressure correctly.

Bucket or boom is jerky

Air in the hydraulic system - Bleed hydraulic system.
Plugged hydraulic oil filter - Change or clean oil filter.
Hydraulic oil contamination - The oil must be changed.
Cylinder tube or rod scoring - Replace failed component.

Hydraulic pump makes excessive noise

Not enough oil or hydraulic system leaking - Top up hydraulic oil or remedy leakage in system.
Clogged hydraulic filter - Change or clean oil filter.
Dirty suction line - Need to clean the suction line.
Air in hydraulic pump - Air bleeding is required.
Pump parts are worn out - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery does not charge

Loose or corroded electrical wiring connections - Clean or tighten wiring connections.
Defective electrical terminal connectors - Install new terminal connectors.
Faulty cell in battery - Change the battery.
Defective or loose belt - Belt needs to be adjusted or replaced.

Starter motor cranks slow

Battery capacity is low - Charge the battery.
Battery discharges quickly - Service battery or replace it.
Bad terminals or disconnected battery cables - Connect cables properly or replace terminals.

Starter is not cranking

Battery is drained or worn - Replace or charge as required.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Battery capacity is low - Low battery charging, charge as required.
Starter motor is faulty - Starter needs to be replaced.