ASV VS-60 Skid Steer Troubleshooting

The ASV VS-60 skid steer loader driveline system components: a 135 cu.in (2.2L) Perkins 404D-22T 4-cycle 4-cylinder turbocharged diesel engine with a rated power of 60 hp (44.7 kW) and 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 17.1 gal/min (65 l/min). The system relief pressure is 3335 psi (230 bar). The ASV VS60 is equipped with a vertical-lift loader boom, 80 ANSI continuous roller chains, and 10x16.5 tires. The skid steer has a maximum lift height of 118" (2995 mm) to hinge pin and dump height of 87" (2210 mm). The rated operating capacity is 2300 lbs (1043 kg), and tipping load is 4600 lbs (2085 kg).

Engine Troubleshooting

Engine difficult to start or won't start

Air in fuel tank - Bleed fuel tank.
Fuel filter element is clogged - Change filter element.
Faulty or dirty injection nozzles - Clean or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Adjustment procedure required.
Fuel injection pump malfunction - Repair or change injection pump.

Engine starts but immediately stalls

Plugged air cleaner - Clean or change cleaner.
Fuel filter element is clogged - Install new filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Defective or clogged fuel injectors - Clean or replace fuel injectors.
Damaged fuel injection pump - Change or repair the pump.

Engine stalls during operation

Engine is not preheated - Warm up to required temperature.
Fuel filter is plugged - Change filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are dirty or defective - If necessary, replace with a new nozzle.
Improper setting of fuel injection pump timing - Adjust fuel injection pump as required.

Engine stalls at low idle speed

Improperly adjusted low idle speed - Adjust the low idle speed.
Fuel injection pump is damaged - Repair or change injection pump.
Fuel injector fault - Clean or replace fuel injectors.
Valve clearance is not correct - Correct valve clearance needs to be set.

Loss of engine power

Plugged air filter - Clean or replace element.
Fuel injection nozzles are faulty or clogged - Clean or change injection nozzles.
Fuel injection pressure is incorrect - Correct the pressure settings.
The valve clearance is incorrect - Adjust valve clearance.
Low idle speed adjustment is incorrect - Correct the settings.
Dirty fuel lines or hoses - Service fuel hoses and lines.
Leaking cylinder head gasket - Install new cylinder head gasket.
Piston rings are worn or defective - Change piston rings.

Engine overheating

Insufficient coolant fluid - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level is insufficient - Check and refill engine oil.
Faulty radiator cap or dirty radiator fins - Clean radiator or replace cap.
Broken or loose fan belt - Fan belt must be replaced.
Engine overload - Reduce engine load.

Oil pressure is insufficient

Low oil level - Add oil as required.
Oil filter clogged - Service or replace engine oil filter.
Different type of engine oil - Use proper viscosity oil.
Crankshaft bearing has excessive oil clearance - Bearings need to be reinstalled.
Defective oil pump - Inspect and change as required.

Engine knocking or noise

Lack of engine oil - Fill up the oil to required level.
Low coolant temperature - Warm up to required temperature.
Fuel injection pump timing is not adjusted - Adjust fuel injection pump as required.
Incorrectly set low idle speed - Need to adjust idle speed.
Damaged or clogged injectors - Test and replace fuel injectors if necessary.
Connecting rod is defective or not aligned - Replace or align connecting rod.
Pistons are worn or scored - Replace the pistons.

Drive System Troubleshooting

Drive system will not operate in either direction

Hydraulic oil level is low - Checking hydraulic oil level and add if necessary.
Faulty drive chain - Inspect drive chain and replace defective components.
Input drive shaft is damaged - Service or change drive shaft.
Relief valve malfunction - Repair or install a new relief valve.
Suction line or hydraulic filter is clogged - Change hydraulic filter or service suction line.
Defective or worn foot or hand controls - Repair or replace.
Worn drive motor or pump - Repair or change faulty component.

Loss of power

Plugged hydraulic oil filter - Replace or service hydraulic filter.
Relief valve is defective or opened - Close or replace relief valve.
Worn or defective transmission parts - Check and change defective components.
Input drive shaft is stuck - Repair or replace faulty drive shaft.
Air in the hydraulic system - Air bleeding is required.

Overheated drive system

Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Hydraulic fluid filter is clogged - Change hydraulic filter.
Defective or worn relief valve - Repair or install a new relief valve.
Hydraulic motor or drive pump is defective - Change or repair faulty component.
Hydraulic oil cooler is dirty - Cooling fins need to be cleaned.
Drive system overloaded continuously - Load needs to be reduced.

Drive system is noisy

Improper oil viscosity - Use correct oil viscosity.
Air in the hydraulic system - Bleed hydraulic system.
Hydraulic motor or drive pump failure - Repair or change faulty component.
Mechanical components of drive system are defective or worn - Inspect drive system and replace faulty components.

Hydraulics Troubleshooting

Hydraulic system has overheating

Incorrect hydraulic pressure setting - Set pressure correctly.
Faulty or improperly adjusted main relief valve - Set up or change the relief valve.
Hydraulic fluid is contaminated - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Check and refill the hydraulic fluid.
Hydraulic pump is worn - Replace or repair pump if necessary.

Boom won't lower or raise

Damaged lift controls - Change or repair.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve failure - Install a new valve or repair it.
Faulty hydraulic cylinder - Replace or repair boom cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Bucket is not working

Bucket controls failure - Change or repair.
Damaged hydraulic oil pump - Repair or change pump if required.
Hydraulic control valve malfunction - Replace or repair the valve.
Bucket cylinder failure - Replace or repair cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm is moving slowly

Faulty hydraulic oil pump - Flow-rate pump and change pump if necessary.
Oil leaks from hydraulic cylinder - Repair leak by replacing the seals.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Defective or not adjusted hydraulic control valve - Repair or adjust correctly.
Hydraulic pressure loss - Adjust pressure correctly.

Bucket or boom is moving jerkily

Air leaks in hydraulic system - Bleed air from system.
Hydraulic oil filter is clogged - Clean or install new filter.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Cylinder tube or rod scoring - Change failed component.

Hydraulic pump makes excessive noise

Hydraulic leaks or low oil level - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is clogged - Service or change hydraulic filter.
Dirty suction line - Need to service the suction line.
Pump is sucking air - Bleed air from hydraulics.
Pump components are faulty - Rebuild or install new pump.

Electrical Troubleshooting

Battery cannot be charged

Electrical wire connections are corroded or loose - Clean or tighten connections.
Faulty battery terminal clamps - Change terminal clamps.
Bad cell in battery - Change the battery.
Belt is worn or loose - Adjust belt tension or change the belt.

Starter motor turns slow

Battery capacity is low - Battery is drained, charge it.
Battery discharges quickly - Service battery or change it.
Disconnected cables or faulty battery terminals - Check wiring connections and replace or clean terminals.

Starter is not cranking

Battery is drained or worn - Replace or charge as required.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery capacity is low - Recharge the battery.
Starter motor failure - Starter needs to be changed.