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ASV RS-60 Troubleshooting

The ASV RS-60 skid steer loader driveline system components: a 135 cu.in (2.2L) Perkins 404D-22T four-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 RS60 is equipped with a radial-lift loader boom, 80 ANSI continuous roller chains, and 10x16.5 tires. The skid steer loader has a boom lifting force of 4750 lbs (2155 kg) and bucket breakout force of 4750 lbs (2155 kg). The rated operating capacity is 2000 lbs (907 kg), and tipping load is 4000 lbs (1814 kg).

Engine Troubleshooting

Engine hard to start or doesn't start
Air in fuel tank - Bleed fuel tank.
Fuel filter element clogging - Change the filter element.
Dirty or faulty injection nozzles - Check injection nozzles and replace if required.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Check and adjust.
Fuel injection pump damage - Change pump or rebuild it.

Diesel starts but stalls immediately
Clogged air filter - Replace or clean air filter element.
Fuel filter element is dirty - Change the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Fuel injection pump is not working correctly - Change pump or rebuild it.

Diesel shuts off while driving
Low coolant temperature - Warm up to required temperature.
Clogged fuel filter - Service or replace the filter.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are clogged or faulty - Check and replace nozzles if required.
Timing of fuel injection pump is incorrect - Adjust the pump as required.

Engine stops when idle
Incorrectly set low idle speed - Adjust as required.
Faulty fuel injection pump - Install a new fuel pump or repair.
Defective fuel injectors - Change or clean fuel injectors.
Improper valve clearance - Correct valve clearance.

Engine power is too low
Clogged air cleaner - Clean or replace element.
Faulty fuel injection nozzles - Replace injection nozzles.
Improper fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve out of adjustment - Adjust valve clearance.
Incorrect low idle speed adjustment - Adjust low idle speed.
Fuel lines or hoses clogging - Fuel hoses and lines must be clean.
Cylinder-head gasket is leaking - Replace the gasket as required.
Piston rings are broken or leaking - Piston rings need to be replaced.

Engine overheated
Coolant level is low - The cooling system needs to be refilled and checked for faults.
Lack of engine oil - Check oil level and add oil as required.
Dirty radiator core or defective radiator cap - Install new cap or clean radiator.
Excessive wear of the fan belt - Belt replacement is recommended.
Engine is under excessive load - Load reducing is recommended.

Oil pressure too low
Lack of oil - Fill the crankcase with oil.
Oil filter element is dirty - Clean or replace engine oil filter element.
Improper type of engine oil - Use proper viscosity oil.
Crankshaft bearing oil clearance is incorrect - Bearings need to be reinstalled.
Oil pump is worn or damaged - Repair or change.

Engine knocking or noise
Engine oil insufficient - Fill the crankcase with engine oil.
Coolant temperature is low - Warm up to required temperature.
Improper setting of fuel injection pump timing - Set it up as required.
Low idle speed setting is incorrect - Test and adjust.
Fuel injectors are faulty or clogged - Replace fuel injectors.
Connecting rod is defective or misaligned - Align or change connecting rod.
Pistons are worn or scored - Replace the pistons.

Drive System Troubleshooting

Drive system does not work in either direction
Low hydraulic oil level - Check and refill the hydraulic oil.
Drive chain is worn - Check drive chain and change defective components.
Damaged input drive shaft - Repair or install a new drive shaft.
Relief valve worn or defective - Repair or change.
Plugged hydraulic filter or suction line - Change hydraulic filter or service suction line.
Damaged or worn hand or foot controls - Replace or repair.
Drive pump or motor malfunction - Inspect and change as required.

Low power
Hydraulic oil filter is plugged - Check, clean, or replace as required.
Relief valve is damaged or open - Replace or close relief valve.
Transmission components are defective or worn - Check and replace faulty components.
Input drive shaft is defective - Service or change faulty drive shaft.
There is air in the hydraulic system - Air bleeding is required.

Drive system keeps overheating
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.
Hydraulic fluid filter is plugged - Replace hydraulic filter.
Relief valve failure - Repair or replace relief valve.
Hydraulic motor or drive pump is worn - Repair or change faulty component.
Dirty oil cooler - Cooling fins should be cleaned.
Drive system is overloaded - Load should be reduced.

Excessive noise
Improper oil viscosity - Use correct oil viscosity.
Air trapped in hydraulic system - Need to bleed air.
Defective drive pump or hydraulic motor - Inspect and replace as necessary.
Worn or defective mechanical parts of drive system - Check the components for worn or defect and replace if necessary.

Hydraulics Troubleshooting

Hydraulic system has overheating
Incorrect hydraulic pressure setting - Hydraulic pressure must be set correctly.
Main relief valve malfunction or improper adjustment - Adjust the valve or replace if necessary.
Hydraulic fluid contamination - Hydraulic fluid change required.
Hydraulic oil level is low - Add oil to the hydraulic system.
Defective hydraulic pump - Repair or install new hydraulic pump.

Boom can't lift or drop
Lift controls failure - Change or repair.
Hydraulic pump is broken - Install new pump or repair it.
Faulty hydraulic control valve - Repair or change hydraulic valve.
Broken hydraulic cylinder - Install a new boom cylinder or repair it.
Low hydraulic oil level - Check and refill the hydraulic oil.

Bucket is not working
Defective bucket controls - Repair or change.
Hydraulic pump is broken - Install new pump or repair it.
Hydraulic control valve failure - Repair or change the valve.
Broken bucket cylinder - Repair or install a new cylinder.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.

Boom or bucket is working slowly
Defective hydraulic pump - Test pump flow rate and replace pump if required.
Leaking hydraulic cylinder - Install new cylinder seals.
Hydraulic oil level low - Check and refill the hydraulic oil.
Faulty or incorrect setting hydraulic control valve - Adjust correctly or repair.
Low hydraulic pressure - Hydraulic pressure must be set correctly.

Bucket or boom is moving jerkily
Air in hydraulic system - Air bleeding is required.
Hydraulic oil filter clogging - Clean or install new filter.
Contaminated hydraulic oil - Change hydraulic oil.
Cylinder tube or rod is scored - Replace damaged component.

Hydraulic pump makes excessive noise
Low oil level or hydraulic leaks - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter is clogged - Replace or clean the filter.
Dirty suction line - Suction line must be serviced.
Air enters the pump - Bleed air.
Worn pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical wire connections are corroded or loose - Tighten or clean connections.
Battery terminal clamps are defective - Terminal clamps should be changed.
Battery is worn - Battery change required.
Worn or loose belt - Change belt or adjust belt tension.

Starter motor turns slow
Low battery capacity - Recharge the battery.
Battery does not hold charge - Battery needs to be serviced or replaced.
Terminals are faulty or battery cables are disconnected - Check cables and clean or change terminals.

Starter will not crank
Battery is drained or defective - Recharge or replace battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Battery is drained, charge it.
Starter motor is damaged - Starter needs to be changed.