ASV RT120 Track Loader Troubleshooting

The ASV RT-120 compact track loader driveline system components: a 232 cu.in (3.8L) Cummins QSF3.8 4-cylinder turbocharged intercooled diesel engine with a rated power of 120 hp (89.5 kW) and hydrostatic transmission with low-high speeds. The hydraulic system has a pump with a rated flow of 20 gpm (75.7 lpm). The system pressure is 3300 psi (227 bar). The ASV RT120 is equipped with radial-lift loader boom, axial-piston drive pumps, and suspended undercarriage with 18.7" (475 mm) rubber tracks. The loader has a max lift height of 125" (3175 mm) to hinge pin. The rated operating capacity is 3535 lbs (1605 kg), and tipping load is 10100 lbs (4580 kg).

Engine Troubleshooting

Engine difficult to start or will not start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element clogging - Clean or replace the filter.
Fuel injection nozzles are clogged or faulty - Install a new kit of correctly balanced nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is not adjusted - Adjustment procedure required.
Fuel injection pump is not operating properly - Replace or rebuild injection pump.

Engine starts but stalls suddenly

Plugged air cleaner - Clean or change cleaner.
Fuel filter element clogging - Clean or change the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Fuel injection pump is not operating properly - Replace or repair injection pump.

Engine stops suddenly during operation

Coolant temperature is low - Warm up to required temperature.
Dirty fuel filter - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are clogged or faulty - Inspect nozzles and replace if necessary.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.

Engine stalls when idling

Low idle speed set incorrectly - Adjust low idle speed.
Fuel injection pump is broken - Repair or install new pump.
Damaged or clogged injectors - Clean or replace fuel injectors.
The valve clearance is incorrect - Adjust valve clearance according to specifications.

Engine lacks power

Air filter is clogged - Clean or replace element.
Damaged or dirty injection nozzles - Clean or change injection nozzles.
Improper fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Valve clearance is not correct - Check and adjust.
Improperly adjusted low idle speed - Correct low idle adjustment.
Restricted fuel lines or hoses - Clean fuel system hoses and lines.
Defective cylinder head gasket - Install a new gasket.
Worn or broken piston rings - Piston rings need to be replaced.

Engine is overheated

Coolant level is low - Fill radiator to proper level and check components for faults.
Insufficient engine oil - Fill up the oil to required level.
Clogged radiator fins or leaking radiator cap - Change cap or clean radiator.
Loose or defective fan belt - Install new fan belt.
Diesel engine overloaded - Reduce engine load.

Oil pressure is insufficient

Oil level is insufficient - Add oil as required.
Plugged engine oil filter - Replace or service engine oil filter.
Improper type of engine oil - Drain crankcase and refill with correct oil.
Excessive main bearing oil clearance - Install new bearings.
Oil pump failure - Check and replace if necessary.

Abnormal engine noise or knocking

Low engine oil level - Need to add engine oil.
Engine is cold - Warm up to required temperature.
Fuel injection pump timing is not adjusted - Adjust according to specifications.
Low idle speed setting is not correct - Normalize low idle speed.
Dirty or defective injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or worn - Need to replace or align the connecting rod.
Pistons are broken or worn - Pistons replacement required.

Drive System Troubleshooting

Machine will not move forward or backward

Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Undercarriage tracks are damaged or blocked - Remedy blockage or repair tracks.
Relief valve is defective - Repair or replace relief valve.
Suction line or hydraulic filter is plugged - Service suction line or change hydraulic filter.
Hand or foot controls failure - Check and repair as required.
Worn drive motor or pump - Check and repair if required.

Machine won't drive straight or drives jerkily

Damaged or jammed track mechanism - Remove jamming or repair tracks.
Tracks are faulty or loose - Replace tracks or adjust track tension.
Foreign objects, debris, or dirt stuck in track frame - Clean track frame, remove debris and foreign objects.

Lack of power

Dirty hydraulic oil filter - Change hydraulic filter.
Relief valve is open or worn - Replace or close relief valve.
Worn or faulty transmission components - Inspect and change faulty parts.
Damaged input drive shaft - Replace drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Drive system overheating

Hydraulic oil level is low - Check and refill the hydraulic oil.
Hydraulic fluid filter is clogged - Replace or clean hydraulic filter.
Stuck relief valve - Change or repair relief valve.
Hydraulic motor or drive pump is defective - Change or repair faulty component.
Dirty oil cooler - Cooling fins should be cleaned.
Drive system overloaded continuously - Load needs to be reduced.

Drive system is noisy

Oil viscosity is too heavy - Use correct oil viscosity.
Hydraulic system is leaking air - Bleed air from hydraulic system.
Hydraulic motor or drive pump is defective - Repair or replace faulty component.
Defective or worn mechanical parts of drive system - Check the parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure is incorrect - Adjust it correctly.
Faulty or improperly adjusted main relief valve - Adjust relief valve or change if required.
Contaminated hydraulic fluid - The fluid must be changed.
Not enough hydraulic fluid in the system - Check and refill the hydraulic fluid.
Hydraulic pump is defective - Repair or change pump if required.

Boom does not raise or lower

Damaged lift controls - Change or repair.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve is faulty - Repair or replace hydraulic valve.
Faulty hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Bucket can't tilt

Bucket tilt controls are damaged - Change or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Hydraulic control valve malfunction - Repair or change hydraulic valve.
Bucket cylinder is faulty - Install a new cylinder or repair it.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Boom or bucket runs slowly

Hydraulic pump is defective - Check hydraulic pump flow and replace pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is faulty or out of adjustment - Adjust correctly or repair.
Hydraulic pressure has dropped - Correct setting is required.

Lift arm or bucket movements are jerky

Air in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is dirty - Service or replace the hydraulic filter.
Hydraulic fluid contamination - Change hydraulic fluid.
Scored cylinder tube or rod - Replace worn component.

Hydraulic pump is noisy

Hydraulic leaks or lack of oil - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is clogged - Clean or change the filter.
Plugged suction line - Clean suction line as required.
Air trapped in hydraulic pump - Need to bleed air.
Faulty pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery will not charge

Electrical cable connections are corroded or loose - Service or tighten cable connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Faulty cell in battery - Battery change required.
Belt is loose or defective - Adjust belt tension or change the belt.

Starter cranks slowly

Low battery voltage - Recharge the battery.
Battery is not holding charge - Service charging system or install new battery.
Disconnected cables or faulty battery terminals - Check wiring connections and replace or clean terminals.

Starter doesn't crank

Battery is low or faulty - Charge or change the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery capacity is low - Charge the battery.
Starter motor failing - Starter should be changed.