ASV RT-25 Track Loader Troubleshooting

The ASV Posi-Track RT-25 compact track loader is powered by 103.7 cu.in (1.7L) Perkins 403J-17T 4-cycle vertical in-line 3-cylinder indirect injection turbocharged diesel engine with a rated power of 24.7 hp (18.4 kW) at 2800 rpm. The ASV RT25 is equipped with 1-speed hydrostatic transmission, axial-piston drive pumps, and 11" (280 mm) rubber tracks with embedded co-polymer cords. The hydraulic system has a gear pump with fluid flow rate of 11.3 gpm (42.8 lpm). The hydraulic pressure is 3000 psi (207 bar). The track loader has a rated operating capacity of 665 lbs (302 kg) and tipping load of 1900 lbs (862 kg). The max lift height is 101" (2565 mm) to hinge pin.

Engine Troubleshooting

Diesel hard to start or doesn't start

Air in fuel system - Bleed fuel system.
Dirty fuel filter - Change filter element.
Damaged or dirty injection nozzles - Clean or replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump is broken - Repair or install a new fuel pump.

Engine stalls after starting

Air filter is plugged - Replace or clean air filter element.
Fuel filter plugged - Clean or replace the filter.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Fuel injection pump is damaged - Install a new fuel pump or repair.

Engine stops suddenly during operation

Low coolant temperature - Warm up the engine.
Clogged fuel filter - Replace the filter element.
Air trapped in fuel system - Bleed air.
Dirty or damaged injection nozzles - Change fuel injection nozzles.
Fuel injection pump timing is not adjusted - Check the fuel injection pump timing adjustment.

Engine stalls at idle

Incorrect low idle speed adjustment - Normalize low idle speed.
Fuel injection pump malfunctioning - Repair or change injection pump.
Damaged or clogged injectors - Inspect fuel injectors and change as required.
Excessive valve clearance - Have it adjusted.

Engine power loss

Air cleaner is clogged - Service or replace air cleaner.
Damaged or dirty injection nozzles - Check and replace nozzles if required.
Incorrect fuel injection pressure - Adjust to correct pressure.
Valve out of adjustment - Have it adjusted.
Improperly adjusted low idle speed - Adjustment required.
Fuel hoses or lines are clogged - Fuel lines and hoses need to be cleaned.
Worn cylinder head gasket - Cylinder-head gasket replacement required.
Leaking or damaged piston rings - Piston rings replacement required.

Engine is overheated

Coolant level is low - Fill radiator to proper level and check components for faults.
Engine oil insufficient - Checking oil level and add if necessary.
Dirty radiator core or faulty radiator cap - Install new cap or clean radiator.
Excessive wear of the fan belt - If necessary, replace the belt.
Engine overloaded - Load reducing is recommended.

Oil pressure is insufficient

Oil level is insufficient - Need to add oil.
Oil filter is clogged - Change or service engine oil filter.
Incorrect oil viscosity - Use oil of proper viscosity.
Main bearing oil clearance is excessive - Bearing needs to be changed.
Oil pump is defective - Inspect and change as required.

Engine knocks or noises

Engine oil insufficient - Need to add engine oil.
Engine is not warmed up to the required temperature - Warm up the engine.
Incorrect adjustment of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Too low idle RPM - Correct low idle settings.
Clogged or defective injectors - Clean fuel injectors or change it.
Faulty or misaligned connecting rod - Align or replace connecting rod.
Broken or worn pistons - Pistons replacement required.

Drive System Troubleshooting

Machine is not moving in one direction or either direction

Low hydraulic oil level - Check and refill the hydraulic oil.
> Track mechanism is defective or jammed - Repair or remedy jamming.
Relief valve failure - Change or repair relief valve.
Plugged suction line or hydraulic filter - Service suction line or change hydraulic filter.
Faulty hand or foot controls - Check and repair as required.
Drive pump or motor malfunction - Repair or change faulty component.

Machine is not moving straight or moving is jerky

Jammed or damaged track mechanism - Repair or remedy jamming.
Loose or worn tracks - Replace tracks or adjust track tension.
Debris, dirt, or foreign objects jammed in undercarriage track frame - Clean undercarriage track frame, remove foreign objects and debris.

Reduced power

Hydraulic oil filter is dirty - Check, clean, or change as necessary.
Relief valve is damaged or open - Close or change relief valve.
Transmission components are faulty or damaged - Check and replace faulty components.
Input drive shaft is worn - Repair or install a new drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Overheated drive system

Hydraulic fluid is insufficient - Add fluid as required.
Dirty hydraulic fluid filter - Check, clean, or change as necessary.
Relief valve is defective - Repair or replace relief valve.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Oil cooler is clogged - Cooling fins need to be cleaned.
Transmission overloading - Load needs to be reduced.

Drive system is noisy

Oil viscosity is wrong - Use oil of proper viscosity.
Air leaks in hydraulic system - Bleed air from hydraulic system.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Mechanical components of drive system are damaged or worn - Check the components for defect or damage and change if necessary.

Hydraulics Troubleshooting

Hydraulic system overheats

Hydraulic pressure is not correct - Hydraulic pressure must be set correctly.
Misadjusted or defective main relief valve - Adjust relief valve or change if required.
Dirty hydraulic fluid - Change hydraulic fluid.
Hydraulic oil level is insufficient - Fill the hydraulic system with oil.
Defective hydraulic pump - Repair or install new hydraulic pump.

Lift arm can't drop or lift

Lift controls failure - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or change pump if required.
Faulty hydraulic control valve - Repair or replace hydraulic valve.
Hydraulic cylinder failure - Repair or replace hydraulic cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.

Bucket does not tilt

Defective bucket controls - Check and repair as required.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Hydraulic bucket cylinder is defective - Repair or replace cylinder.
Hydraulic oil is insufficient - Need to add oil.

Bucket or lift arm functions slowly

Hydraulic pump is worn - Check pump capacity and change if necessary.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Hydraulic fluid is insufficient - Add fluid as required.
Hydraulic control valve is defective or set improper - Repair or set correctly.
Hydraulic pressure is low - Adjust pressure correctly.

Bucket or boom jerks when working

Air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element is clogged - Service or change the hydraulic filter.
Hydraulic fluid is contaminated - Change hydraulic fluid.
Scratched cylinder rod or tube - Replace defective component.

Hydraulic pump is noisy

Leaking hydraulic system or insufficient oil level - Refill hydraulic oil or repair leaks in system.
Hydraulic filter is dirty - Service or replace hydraulic filter.
Plugged suction line - Clean suction line as required.
Air trapped in hydraulic pump - Need to bleed air.
Damaged pump components - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery cannot be charged

Wiring connections are loose or corroded - Tighten or service connections.
Battery terminal clamps are faulty - Terminal clamps need to be replaced.
Battery dead cell - Install a new battery.
Loose or worn belt - Adjust belt tension or replace belt.

Starter motor cranks slow

Low battery output voltage - Low battery charging, charge as required.
Battery won’t hold charge - Service or change the battery.
Bad terminals or disconnected battery cables - Connect cables correctly or replace terminals.

Starter is not working

Battery is low or faulty - Charge or change the battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery voltage is low - Battery needs to be recharged.
Starter motor is defective - Replace or repair starter.