ASV RT120F Track Loader Troubleshooting

The ASV RT-120 Forestry compact track loader is powered by 232 cu.in (3.8L) Cummins QSF3.8 vertical 4-cylinder turbocharged intercooled diesel engine with a rated power of 120 hp (89.5 kW) at 2800 rpm. The ASV RT120F is equipped with a two-speed hydrostatic transmission, radial-lift loader boom, 20" (505 mm) rubber tracks, and elevated track drive sprockets. The hydraulic system has an axial-piston pump with fluid flow rate of 20 gpm (75.7 lpm). The hydraulic pressure is 3300 psi (227 bar). The track loader has a rated operating capacity of 3745 lbs (1700 kg) and tipping load of 10700 lbs (4855 kg). The maximum lift height is 125" (3175 mm) to hinge pin.

Engine Troubleshooting

Engine hard to start or will not start

There is air in the fuel system - Bleed the system.
Fuel filter element is dirty - Filter maintenance required.
Dirty or faulty injection nozzles - Clean or replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve out of adjustment - Adjust valve clearance.
Fuel injection pump is not working correctly - Replace injection pump or repair it.

Engine starts and immediately shuts off

Air filter is dirty - Change or service air filter element.
Fuel filter element is clogged - Change the filter element.
Fuel injection pump is leaking - Repair any leaks.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Fuel injection pump malfunction - Install a new fuel pump or repair.

Engine stalls while running

Engine is not preheated - Warm up the engine as required.
Dirty fuel filter - Clean the filter or install new filter element.
Air in the fuel system - Air bleeding.
Fuel injection nozzles fault - Install a new kit of correctly balanced nozzles.
Fuel injection pump timing is wrong - Use the correct fuel injection pump timing adjustment.

Engine stalls at low idle speed

Improperly adjusted low idle speed - Correct low idle settings.
Fuel injection pump is not working correctly - Replace or repair injection pump.
Clogged or defective injectors - Change or clean fuel injectors.
Valve out of adjustment - Need to adjust valve clearance.

Loss of engine power

Dirty air filter - Clean or change filter.
Faulty or dirty injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is wrong - Test fuel injection pressure and adjust it correctly.
Excessive valve clearance - Adjust valve clearance.
Incorrectly adjusted low idle speed - Need to adjust idle speed.
Dirty fuel lines or hoses - Clean fuel hoses and lines.
Cylinder-head gasket is broken - Cylinder-head gasket replacement required.
Piston rings are defective or leaking - Replace piston rings.

Engine overheats

Insufficient coolant - Refill to the correct level and inspect system for leaks.
Engine oil insufficient - Fill up the engine oil.
Clogged radiator fins or damaged radiator cap - Clean radiator or install new cap.
Damaged or worn fan belt - Replace as required.
Engine is under excessive load - Load reducing required.

Oil pressure is low

Engine oil insufficient - Fill crankcase to proper oil level.
Dirty oil filter - Clean or change engine oil filter.
Incorrect engine oil Use the specified type of engine oil.
Incorrect oil clearance in crankshaft bearing - Bearings need to be reinstalled.
Oil pump failure - Replace as required.

Engine knocking or noise

Engine oil level low - Fill the crankcase with engine oil.
Engine not warmed up - Warm up the engine as required.
Improper fuel injection timing - Set it up as required.
Wrong adjustment of low idle speed - Adjust the low idle speed.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Connecting rod is not aligned or worn - Need to align or replace the connecting rod.
Piston wear or scoring - Install new pistons.

Drive System Troubleshooting

Drive system won't operate in either direction

Insufficient hydraulic oil - Check and refill the hydraulic oil.
Blocked or defective track mechanism - Correct blockage or repair tracks.
Relief valve malfunction - Repair or install a new relief valve.
Suction line or hydraulic filter is clogged - Check, clean, or replace if required.
Foot or hand controls are faulty - Repair or replace.
Drive pump or motor is damaged - Replace or repair faulty component.

Machine does not drive straight or drives jerky

Undercarriage tracks are defective or jammed - Repair or remedy jamming.
Sagging or faulty tracks - Replace tracks or adjust track sag with tension.
Undercarriage track frame is plugged with dirt, debris, or foreign objects - Clean undercarriage track frame, remove foreign objects and debris.

Loss of power

Clogged hydraulic oil filter - Change or clean hydraulic filter.
Defective or open relief valve - Close or change relief valve.
Faulty or damaged transmission components - Check and change defective components.
Input drive shaft is damaged - Repair or replace faulty drive shaft.
Air in hydraulic system - Bleed air from hydraulic system.

Drive system is overheated

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Plugged hydraulic fluid filter - Change hydraulic filter.
Relief valve is defective - Repair or replace.
Defective drive pump or hydraulic motor - Check and repair if required.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Overloaded drive system - Reduce drive system load.

Drive system is excessively noisy

Wrong oil viscosity - Use the specified type of oil.
Air leaks in hydraulic system - Bleed air from system.
Hydraulic motor or drive pump failure - Repair or change faulty component.
Mechanical components of drive system are worn or damaged - Inspect the parts for worn or defect and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheated

Incorrect hydraulic pressure setting - Correct adjustment is required.
Unadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Dirty hydraulic oil - The oil must be changed.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Defective hydraulic pump - Repair or install new hydraulic pump.

Lift arm won't raise or lower

Lift controls malfunction - Inspect and repair if necessary.
Hydraulic pump not working - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or change the valve.
Hydraulic cylinder is broken - Change or repair lift cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket fails to tilt

Faulty bucket tilt controls - Check and repair as required.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve failure - Repair or change the valve.
Broken bucket cylinder - Repair or install a new cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Boom or bucket moves slowly

Hydraulic pump is faulty - Check pump performance and change it if necessary.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Defective or not adjusted hydraulic control valve - Set correctly or repair.
Low hydraulic pressure - Correct setting is required.

Bucket or boom is working jerkily

Air leaks in hydraulic system - Bleed air from system.
Dirty hydraulic oil filter element - Service or replace the hydraulic filter.
Dirty hydraulic fluid - The fluid must be changed.
Cylinder tube or rod is scored - Change worn component.

Hydraulic pump makes excessive noise

Hydraulic leakage or low oil level - Repair hydraulic leaks or add oil as required.
Plugged hydraulic filter - Clean or change the filter.
Dirty suction line - Suction line needs to be cleaned.
Pump sucks air - Air bleeding is required.
Pump components are worn out - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery is not charging

Electrical wire connections are loose or corroded - Tighten or service connections.
Electrical terminal connectors are defective - Terminal connectors should be replaced.
Battery is worn - Use a new battery.
Loose or damaged belt - Adjust belt tension or change the belt.

Starter cranks slowly

Low battery capacity - Charge the battery.
Battery won’t hold charge - Battery needs service or replacement.
Faulty battery terminals or disconnected cables - Check wiring and clean or replace terminals.

Starter will not crank

Battery is drained or worn - Need to charge or replace the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Low battery charging, charge as required.
Faulty starter motor - Repair or replace starter.