ASV RT-60 Track Loader Troubleshooting

The ASV Posi-Track RT-60 compact track loader driveline system components: a 135 cu.in (2.2L) Perkins 404D-22T 4-cylinder turbocharged diesel engine with a rated power of 60 hp (44.7 kW), and 2-speed hydro transmission. The hydraulic system has a pump with a rated flow of 17.4 gpm (66 lpm). The system pressure is 3000 psi (207 bar). The ASV RT60 is equipped with axial-piston drive pumps, suspended undercarriage, and 15" (380 mm) rubber tracks. The loader has a max lift height of 115.5" (2920 mm) to hinge pin and dump height of 91" (2310 mm). The rated operating capacity is 1900 lbs (860 kg), and tipping load is 5430 lbs (2463 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start

There is air in the fuel system - Bleed the system.
Clogged fuel filter - Filter maintenance required.
Burnt or defective injection nozzle - If necessary, replace with a new nozzle.
Water in the fuel system - Change fuel and repair fuel system.
Incorrect valve clearance - Check and adjust.
Fuel injection pump damage - Repair or replace injection pump.

Engine starts but then stalls

Plugged air cleaner - Clean or replace air cleaner element.
Fuel filter plugged - Change filter element.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Clean or replace fuel injectors.
Fuel injection pump is faulty - Install a new fuel pump or repair.

Engine stops unexpectedly during operation

Engine is cold - Warm up to required temperature.
Fuel filter element clogging - Clean the filter or install new filter element.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles fault - Check injection nozzles and replace if required.
Improper fuel injection timing - Set up as recommended.

Engine stalls while idling

Wrong adjustment of low idle speed - Adjust the low idle speed.
Fuel injection pump damage - Replace or repair injection pump.
Fuel injectors are faulty or clogged - Replace or clean fuel injectors.
The valve clearance is not adjusted - Need to adjust valve clearance.

Diesel power loss

Air cleaner is clogged - Service or replace air cleaner.
Clogged or burnt injection nozzle - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
Improper valve clearance - Adjust to proper valve clearance.
Incorrectly set low idle speed - Test and adjust.
Dirt in the fuel hoses or lines - Service fuel lines and hoses.
Cylinder-head gasket is broken - Replace the gasket as required.
Piston rings are leaking or defective - Piston rings need to be replaced.

Engine overheats

Lack of engine coolant - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level low - Check and refill engine oil.
Dirty radiator fins or defective radiator cap - Replace cap or clean radiator.
Fan belt is worn or faulty - If necessary, replace the belt.
Diesel engine overloaded - Load reducing required.

Insufficient oil pressure

Lack of oil - Add oil as required.
Clogged oil filter - Service or change engine oil filter element.
Different type of engine oil - Use proper viscosity oil.
Crankshaft bearing has incorrect oil clearance - Install new bearings.
Worn oil pump - Inspect and change as required.

Abnormal engine noise or knocking

Engine oil level is insufficient - Checking oil level and add if necessary.
Engine not warmed up - Warm up the engine.
Improper setting of fuel injection pump timing - Adjust the pump as required.
Low idle speed adjustment is incorrect - Need to adjust idle speed.
Dirty or defective injectors - Replace fuel injectors.
Connecting rod is not aligned or defective - Alignment procedure or replacement is required.
Worn or scored pistons - Pistons need to be replaced.

Drive System Troubleshooting

Machine does not move forward or backward

Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Jammed or damaged undercarriage tracks - Remove jamming or repair tracks.
Defective relief valve - Rebuild or install a new relief valve.
Hydraulic filter or suction line is plugged - Service suction line or change hydraulic filter.
Foot or hand controls are defective - Check and repair as required.
Defective drive pump or motor - Repair or replace faulty component.

Machine does not move straight or moves jerky

Damaged or jammed track mechanism - Repair or fix jamming.
Tracks are improperly tensioned or faulty - Adjust track tension or replace tracks.
Track frame is blocked with debris, dirt, or foreign objects - Remove debris or foreign objects and clean track frame.

Power is too low

Hydraulic oil filter is plugged - Change or service hydraulic filter.
Relief valve is open or defective - Replace or close relief valve.
Faulty or damaged transmission components - Inspect and change faulty parts.
Damaged input drive shaft - Repair or replace drive shaft.
Air leaks in hydraulic system - Bleed hydraulic system.

Drive system is overheated

Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Clogged hydraulic fluid filter - Change hydraulic filter.
Defective or worn relief valve - Relief valve need to be replaced or repair.
Defective drive pump or hydraulic motor - Check and repair if required.
Plugged hydraulic oil cooler - Clean cooling fins as required.
Overloaded drive system - Load needs to be reduced.

Drive system makes excessive noise

Oil viscosity is wrong - Use oil of correct viscosity.
Hydraulic system is leaking air - Bleed hydraulic system.
Hydraulic motor or drive pump is defective - Check and repair if required.
Mechanical components of drive system are worn or damaged - Inspect the parts for worn or defect and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheats

Hydraulic pressure is incorrect - Adjust pressure as required.
Unadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Hydraulic fluid is contaminated - Fill up with fresh hydraulic fluid.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Hydraulic pump is faulty - Install new pump or repair it.

Boom won't lower or raise

Lift controls are defective - Repair or change.
Defective hydraulic pump - Repair or replace pump if necessary.
Hydraulic control valve is faulty - Install a new valve or repair it.
Hydraulic cylinder malfunction - Change or repair lift cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Bucket does not function

Bucket tilt controls are defective - Replace or repair.
Hydraulic pump is broken - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Repair or change hydraulic valve.
Hydraulic bucket cylinder is defective - Install a new cylinder or repair it.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Boom or bucket functions slowly

Worn hydraulic oil pump - Check hydraulic pump flow and replace pump if necessary.
Hydraulic cylinder leaking - Correct leakage by changing the seals.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is faulty or out of adjustment - Repair or adjust properly.
Hydraulic pressure is low - Set pressure correctly.

Lift arm or bucket movements are jerky

Air in the hydraulic system - Air bleeding is required.
Hydraulic oil filter is clogged - Clean or change the filter.
Dirty hydraulic fluid - Hydraulic fluid change required.
Cylinder rod or tube is scratched - Replace failed component.

Hydraulic pump is excessively noisy

Hydraulic leaks or lack of oil - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Clean or install new filter.
Suction line is dirty - Need to service the suction line.
Air in hydraulic pump - Bleed air from hydraulics.
Pump components are worn out - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging

Electrical wire connections are corroded or loose - Tighten or service cable connections.
Defective battery terminal connectors - Terminal connectors need to be changed.
Faulty cell in battery - Use a new battery.
Belt is defective or loose - Install a new belt or adjust belt tension.

Starter cranks slow

Low battery output - Battery needs to be recharged.
Battery will not hold charge - Battery needs to be serviced or replaced.
Battery terminals are corroded or wires are disconnected - Connect cables correctly or replace terminals.

Starter motor won't turn

Battery is drained or defective - Battery needs to be recharged or replaced.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery voltage is low - Low battery charging, charge as required.
Defective starter motor - Repair or change starter.