New Holland C238 Track Loader Troubleshooting

The New Holland C238 compact track loader is powered by 207 cu.in (3.4 L) FPT F5B FL413E 4-cylinder turbocharged liquid-cooled diesel engine with a rated power of 84 hp (62 kW) at 2500 rpm. The New Holland C238 is equipped with a two-speed hydrostatic transmission, hydraulic disc brakes, and steel-embedded rubber tracks. The hydraulic system has a pump with fluid flow rate of 24.2 gpm (91.5 lpm). The hydraulic pressure is 3050 psi (210 bar). The compact track loader has a rated operating capacity of 2660 lbs (1210 kg) and tipping load of 7600 lbs (3445 kg). The lift height is 131.1 inches (3330 mm) to hinge pin, and dump height is 104.5 inches (2655 mm).

Engine Troubleshooting

Engine starts up hard or doesn't start

Air in fuel tank - Bleed fuel tank.
Fuel filter element is clogged - Clean the filter or install new filter element.
Defective or clogged injection nozzle - Change fuel injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Have it adjusted.
Fuel injection pump damage - Replacement or repair required.

Engine starts and stalls suddenly

Plugged air filter - Service or replace the air filter.
Fuel filter plugged - Clean or replace the filter.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Damaged or clogged injectors - Inspect fuel injectors and change as required.
Fuel injection pump is not operating properly - Rebuild or install a new injection pump.

Engine stops suddenly during operation

Low coolant temperature - Warm up the engine.
Fuel filter is plugged - Service or replace the filter.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles are dirty or defective - Service or change injection nozzles.
Incorrect adjustment of fuel injection pump timing - Adjust according to specifications.

Engine stops while idling

Too low idle RPM - Adjust low idle speed.
Fuel injection pump is not operating properly - Replacement or repair required.
Defective fuel injectors - Replace fuel injectors.
The valve clearance is not adjusted - Adjust valve clearance.

Engine loses power

Air filter is clogged - Clean or replace element.
Faulty fuel injection nozzles - Clean or change injection nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
Incorrect valve clearance - Adjust valve clearance.
Incorrectly set low idle speed - Adjustment required.
Fuel hoses or lines are dirty - Service fuel lines and hoses.
Worn cylinder head gasket - Replace the gasket as required.
Piston rings are worn or damaged - Piston rings need to be replaced.

Engine overheated

Insufficient coolant - Refill to the correct level and inspect system for leaks.
Engine oil level low - Add oil to the engine crankcase.
Damaged radiator cap or dirty radiator core - Clean radiator or change cap.
Loose or defective fan belt - Change as required.
Engine overloaded - Reduce engine load.

Insufficient oil pressure

Engine oil level low - Fill up the engine oil.
Oil filter clogging - Change or service engine oil filter.
Oil grade or viscosity is wrong - Drain crankcase and refill with correct oil.
Crankshaft bearing has excessive oil clearance - Change bearings.
Defective oil pump - Repair or replace.

Engine knocking sound or abnormal noise

Insufficient engine oil - Fill up the oil to required level.
Engine is not preheated - Normalize the temperature by warming up the engine.
Fuel injection pump timing is wrong - Use the correct fuel injection pump timing adjustment.
Too low idle RPM - Normalize low idle speed.
Defective fuel injectors - Clean or replace fuel injectors.
Connecting rod misalignment or failure - Need to align or replace the connecting rod.
Worn or broken pistons - Install new pistons.

Drive System Troubleshooting

Drive system won't operate in either direction

Hydraulic oil is insufficient - Check and refill the hydraulic oil.
Undercarriage tracks are jammed or defective - Repair or remove jamming.
Relief valve is defective - Repair or replace.
Suction line or hydraulic filter is clogged - Service suction line or change hydraulic filter.
Defective hand or foot controls - Check and repair as required.
Drive motor or pump failure - Replace or repair faulty component.

Machine is not moving straight or moving is jerky

Undercarriage tracks are jammed or defective - Fix jamming or repair tracks.
Tracks are improperly tensioned or faulty - Adjust track tension or repair tracks.
Debris or dirt jammed in undercarriage track frame - Remove debris or clean track frame.

Loss of power

Hydraulic oil filter is plugged - Change or service hydraulic filter.
Relief valve is damaged or open - Close or change relief valve.
Transmission components are worn or defective - Inspect and change defective parts.
Input drive shaft malfunction - Repair or install a new drive shaft.
Air in hydraulic system - Bleed air from hydraulic system.

Drive system keeps overheating

Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Hydraulic fluid filter is plugged - Change hydraulic filter.
Relief valve malfunction - Service or change relief valve.
Hydraulic motor or drive pump failure - Check and repair if required.
Oil cooler is clogged - Clean the cooling fins.
Overloaded drive system - Reduce loading.

Drive system is excessively noisy

Incorrect oil viscosity - Use oil of correct viscosity.
Air trapped in hydraulic system - Bleed air from system.
Drive pump or hydraulic motor is damaged - Inspect and replace as necessary.
Mechanical components of drive system are defective or worn - Check the parts and change if required.

Hydraulics Troubleshooting

Hydraulic system overheating

Incorrect hydraulic pressure setting - Adjust pressure correctly.
Main relief valve failure or improper setting - Adjust relief valve or change if required.
Dirty hydraulic oil - Hydraulic oil change required.
Lack of hydraulic oil - Add oil to the hydraulic system.
Hydraulic pump is defective - Install new pump or repair it.

Lift arm cannot be raised or lowered

Lift controls failure - Repair or replace.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic cylinder not working - Install a new boom cylinder or repair it.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Bucket is not working

Bucket tilt controls malfunction - Repair or change.
Hydraulic pump malfunction - Install new pump or repair it.
Defective hydraulic control valve - Repair or replace hydraulic valve.
Broken bucket cylinder - Install a new cylinder or repair it.
Insufficient hydraulic fluid - Add fluid as required.

Boom or bucket functions slowly

Hydraulic pump is defective - Test the pump flow rate and install new pump if required.
Leaking hydraulic cylinder - Change cylinder piston seals.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.
Defective or not adjusted hydraulic control valve - Adjust properly or repair.
Hydraulic system loosing pressure - Hydraulic pressure must be set correctly.

Bucket or boom is jerky

Air trapped in hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil filter element - Clean or replace the filter.
Contaminated hydraulic oil - The oil must be changed.
Scratched cylinder rod or tube - Change damaged component.

Excessive hydraulic pump noise

Hydraulic system leaking or not enough oil - Top up hydraulic oil or remedy leakage in system.
Clogged hydraulic filter - Clean or install new filter.
Plugged suction line - Suction line needs to be cleaned.
Air in hydraulic pump - Air bleeding is required.
Worn pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery won’t charge

Corroded or loose electrical wire connections - Tighten or clean connections.
Defective battery terminal clamps - Terminal clamps need to be replaced.
Battery is worn - Use a new battery.
Defective or loose belt - Replace belt or adjust belt tension.

Starter cranks slowly

Low battery voltage - Battery is drained, recharge it.
Battery runs out quickly - Service charging system or install new battery.
Faulty battery terminals or disconnected cables - Check wire connections and change or service terminals.

Starter motor won't turn

Battery is discharged or worn - Replace or charge as required.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery output voltage - Battery is drained, recharge it.
Starter motor is faulty - Starter needs to be changed.