ASV RT-65 Track Loader Troubleshooting

The ASV RT-65 compact track loader driveline system components: a 134 cu.in (2.2L) Deutz TCD2.2-T4F 4-cylinder turbocharged diesel engine with a rated power of 67 hp (50 kW) and single-speed hydro transmission. The hydraulic system has a pump with a rated flow of 27.4 gpm (103.7 lpm). The system pressure is 3300 psi (227 bar). The ASV RT65 is equipped with radial-lift loader boom, 15" (380 mm) rubber tracks, and elevated track drive sprockets. The loader has a maximum lift height of 116.5" (2960 mm) to hinge pin and dump height of 87.5" (2225 mm). The rated operating capacity is 1925 lbs (873 kg), and tipping load is 5500 lbs (2495 kg).

Engine Troubleshooting

Engine starts hard or doesn't start

Air in the fuel lines - Bleed the fuel lines.
Fuel filter element clogging - Change filter element.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is not correct - Adjust valve clearance.
Fuel injection pump failure - Rebuild or replace pump.

Diesel starts but stalls immediately

Clogged air filter - Clean or change filter.
Fuel filter plugging - Install new filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Damaged or clogged injectors - Replace or clean fuel injectors.
Defective fuel injection pump - Rebuild or install a new injection pump.

Engine shuts off suddenly while running

Engine is not preheated - Engine is not warmed up to the required temperature.
Fuel filter is plugged - Change filter element.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are clogged or faulty - Replace injection nozzles.
Improper fuel injection timing - Set the fuel pump timing correctly.

Engine stalls when idle

Too low idle RPM - Correct low idle settings.
Damaged fuel injection pump - Replacement or repair required.
Defective fuel injectors - Replace fuel injectors.
Incorrect valve clearance - Correct valve clearance needs to be set.

Engine loses power

Clogged air cleaner - Clean or replace air cleaner element.
Clogged or burnt injection nozzle - Check injection nozzles and replace if required.
Improper fuel injection pressure - Adjust pressure to proper level.
The valve clearance is incorrect - Adjust to proper valve clearance.
Improperly adjusted low idle speed - Correct low idle settings.
Fuel hoses or lines are dirty - Clean fuel system lines and hoses.
Worn cylinder head gasket - Gasket should be replaced.
Piston rings are worn or damaged - Change piston rings.

Engine overheating

Insufficient coolant - Add coolant and check the components of cooling system.
Engine oil level low - Fill up the engine oil.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Fan belt slipping or worn - Change as required.
Engine overload - Load reducing is recommended.

Insufficient oil pressure

Insufficient engine oil - Add oil as required.
Oil filter element clogged - Replace or clean engine oil filter element.
Wrong oil viscosity - Use correct viscosity oil.
Excessive main bearing oil clearance - Bearing needs to be changed.
Oil pump is defective - Install a new pump.

Engine noise or knocking

Engine oil level is low - Checking oil level and add if necessary.
Coolant temperature is low - Warm up engine as required.
Fuel injection pump timing is wrong - Set up as recommended.
Improperly adjusted low idle speed - Normalize low idle speed.
Dirty or defective injectors - Clean or replace fuel injectors.
Connecting rod failure or misalignment - Need to change or align the connecting rod.
Pistons are worn or scored - Install new pistons.

Drive System Troubleshooting

Drive system doesn't operate in one direction or either direction

Hydraulic fluid level low - Fill up the hydraulic fluid.
Undercarriage tracks are jammed or defective - Repair or remedy jamming.
Defective relief valve - Repair or change.
Suction line or hydraulic filter is plugged - Check, clean, or change if necessary.
Foot or hand controls are defective - Repair or replace.
Drive motor or pump failure - Repair or replace faulty component.

Machine does not drive straight or drives jerky

Track mechanism is defective or jammed - Repair or fix jamming.
Faulty or loose tracks - Adjust track tension as required or replace tracks.
Foreign objects, debris, or dirt jammed in track frame - Remove debris or foreign objects and clean track frame.

Loss of power

Clogged hydraulic oil filter - Change or clean hydraulic filter.
Relief valve is damaged or open - Close or replace relief valve.
Faulty or damaged transmission components - Inspect and change defective parts.
Defective input drive shaft - Rebuild or change the shaft.
Hydraulic system is leaking air - Bleed hydraulic system.

Drive system is overheated

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Plugged hydraulic fluid filter - Replace or service hydraulic filter.
Relief valve failure - Relief valve need to be replaced or repair.
Hydraulic motor or drive pump failure - Repair or change faulty component.
Clogged hydraulic oil cooler - Cooling fins need to be cleaned.
Transmission overloading - Reduce the load.

Drive system makes excessive noise

Oil viscosity is incorrect - Use the specified type of oil.
Air in hydraulic system - Bleed air from hydraulic system.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Worn or damaged mechanical parts of drive system - Inspect the parts for defect or damage and repair as required.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure is not correct - Adjust it correctly.
Main relief valve is damaged or adjusted improperly - Adjust relief valve or change if required.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Need to add fluid.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Boom can't lift or drop

Faulty lift controls - Replace or repair.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Install a new hydraulic valve or repair it.
Broken hydraulic cylinder - Install a new boom cylinder or repair it.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.

Bucket fails to tilt

Faulty bucket tilt controls - Inspect and repair if necessary.
Hydraulic pump not working - Repair or change pump if required.
Damaged hydraulic control valve - Replace or repair the valve.
Hydraulic bucket cylinder is broken - Repair or change cylinder.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.

Slow bucket or lift arm operation

Hydraulic pump is worn - Test pump performance and replace pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic fluid - Add fluid as required.
Hydraulic control valve is unadjusted or worn - Repair or set properly.
Hydraulic pressure has dropped - Adjust pressure correctly.

Bucket or boom is working jerkily

Air in the hydraulic system - Bleed air from system.
Hydraulic oil filter element is dirty - Change or clean oil filter.
Hydraulic fluid contamination - Fill up with fresh hydraulic fluid.
Cylinder rod or tube is scuffed - Change failed component.

Hydraulic pump is excessively noisy

Hydraulic leaks or low oil level - Repair hydraulic leaks or add oil as required.
Clogged hydraulic filter - Clean or install new filter.
Suction line clogging - Suction line needs to be cleaned.
Pump is sucking air - Bleed air.
Pump components are worn out - Change or rebuild pump.

Electrical Troubleshooting

Battery will not charge

Wiring connections are corroded or loose - Tighten or clean electrical wiring connections.
Defective electrical terminal connectors - Terminal connectors should be replaced.
Faulty cell in battery - Battery replacement required.
Belt is defective or loose - Adjust belt tension or install a new belt.

Starter turns slowly

Low battery capacity - Charge the battery.
Battery does not hold charge - Service charging system or change battery.
Disconnected cables or faulty battery terminals - Check wiring connections and replace or clean terminals.

Starter is not working

Battery is drained or worn - Recharge or replace battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery output - Battery needs to be recharged.
Starter motor failing - Starter should be changed.