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ASV RT120 Troubleshooting
The
ASV RT-120 compact track loader driveline system components: a 232 cu.in (3.8L)
Cummins QSF3.8 4-cylinder turbocharged intercooled diesel engine with a
rated power of 120 hp (89.5 kW) and hydrostatic transmission with low-high
speeds. The hydraulic system has a pump with a rated flow of 20 gpm (75.7 lpm).
The system pressure is 3300 psi (227 bar). The ASV RT120 is equipped with
radial-lift loader boom, axial-piston drive pumps, and suspended undercarriage
with 18.7" (475 mm) rubber tracks. The loader has a max lift height of 125"
(3175 mm) to hinge pin. The rated operating capacity is 3535 lbs (1605 kg), and
tipping load is 10100 lbs (4580 kg).
| Engine Troubleshooting |
Engine difficult to start or will not start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element clogging - Clean or replace the filter.
Fuel injection nozzles are clogged or faulty - Install a new kit of correctly balanced nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is not adjusted - Adjustment procedure required.
Fuel injection pump is not operating properly - Replace or rebuild injection pump.
Engine starts but stalls suddenly
Plugged air cleaner - Clean or change cleaner.
Fuel filter element clogging - Clean or change the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Fuel injection pump is not operating properly - Replace or repair injection pump.
Engine stops suddenly during operation
Coolant temperature is low - Warm up to required temperature.
Dirty fuel filter - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are clogged or faulty - Inspect nozzles and replace if necessary.
Timing of fuel injection pump is incorrect - Set the fuel pump timing correctly.
Engine stalls when idling
Low idle speed set incorrectly - Adjust low idle speed.
Fuel injection pump is broken - Repair or install new pump.
Damaged or clogged injectors - Clean or replace fuel injectors.
The valve clearance is incorrect - Adjust valve clearance according to specifications.
Engine lacks power
Air filter is clogged - Clean or replace element.
Damaged or dirty injection nozzles - Clean or change injection nozzles.
Improper fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Valve clearance is not correct - Check and adjust.
Improperly adjusted low idle speed - Correct low idle adjustment.
Restricted fuel lines or hoses - Clean fuel system hoses and lines.
Defective cylinder head gasket - Install a new gasket.
Worn or broken piston rings - Piston rings need to be replaced.
Engine is overheated
Coolant level is low - Fill radiator to proper level and check components for faults.
Insufficient engine oil - Fill up the oil to required level.
Clogged radiator fins or leaking radiator cap - Change cap or clean radiator.
Loose or defective fan belt - Install new fan belt.
Diesel engine overloaded - Reduce engine load.
Oil pressure is insufficient
Oil level is insufficient - Add oil as required.
Plugged engine oil filter - Replace or service engine oil filter.
Improper type of engine oil - Drain crankcase and refill with correct oil.
Excessive main bearing oil clearance - Install new bearings.
Oil pump failure - Check and replace if necessary.
Abnormal engine noise or knocking
Low engine oil level - Need to add engine oil.
Engine is cold - Warm up to required temperature.
Fuel injection pump timing is not adjusted - Adjust according to specifications.
Low idle speed setting is not correct - Normalize low idle speed.
Dirty or defective injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or worn - Need to replace or align the connecting rod.
Pistons are broken or worn - Pistons replacement required.
| Drive System Troubleshooting |
Machine will not move forward or backward
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Undercarriage tracks are damaged or blocked - Remedy blockage or repair tracks.
Relief valve is defective - Repair or replace relief valve.
Suction line or hydraulic filter is plugged - Service suction line or change hydraulic filter.
Hand or foot controls failure - Check and repair as required.
Worn drive motor or pump - Check and repair if required.
Machine won't drive straight or drives jerkily
Damaged or jammed track mechanism - Remove jamming or repair tracks.
Tracks are faulty or loose - Replace tracks or adjust track tension.
Foreign objects, debris, or dirt stuck in track frame - Clean track frame, remove debris and foreign objects.
Lack of power
Dirty hydraulic oil filter - Change hydraulic filter.
Relief valve is open or worn - Replace or close relief valve.
Worn or faulty transmission components - Inspect and change faulty parts.
Damaged input drive shaft - Replace drive shaft.
Air trapped in hydraulic system - Need to bleed air.
Drive system overheating
Hydraulic oil level is low - Check and refill the hydraulic oil.
Hydraulic fluid filter is clogged - Replace or clean hydraulic filter.
Stuck relief valve - Change or repair relief valve.
Hydraulic motor or drive pump is defective - Change or repair faulty component.
Dirty oil cooler - Cooling fins should be cleaned.
Drive system overloaded continuously - Load needs to be reduced.
Drive system is noisy
Oil viscosity is too heavy - Use correct oil viscosity.
Hydraulic system is leaking air - Bleed air from hydraulic system.
Hydraulic motor or drive pump is defective - Repair or replace faulty component.
Defective or worn mechanical parts of drive system - Check the parts for worn or defect and replace if required.
| Hydraulics Troubleshooting |
Hydraulic system has overheating
Hydraulic pressure is incorrect - Adjust it correctly.
Faulty or improperly adjusted main relief valve - Adjust relief valve or change if required.
Contaminated hydraulic fluid - The fluid must be changed.
Not enough hydraulic fluid in the system - Check and refill the hydraulic fluid.
Hydraulic pump is defective - Repair or change pump if required.
Boom does not raise or lower
Damaged lift controls - Change or repair.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve is faulty - Repair or replace hydraulic valve.
Faulty hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.
Bucket can't tilt
Bucket tilt controls are damaged - Change or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Hydraulic control valve malfunction - Repair or change hydraulic valve.
Bucket cylinder is faulty - Install a new cylinder or repair it.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.
Boom or bucket runs slowly
Hydraulic pump is defective - Check hydraulic pump flow and replace pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is faulty or out of adjustment - Adjust correctly or repair.
Hydraulic pressure has dropped - Correct setting is required.
Lift arm or bucket movements are jerky
Air in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is dirty - Service or replace the hydraulic filter.
Hydraulic fluid contamination - Change hydraulic fluid.
Scored cylinder tube or rod - Replace worn component.
Hydraulic pump is noisy
Hydraulic leaks or lack of oil - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is clogged - Clean or change the filter.
Plugged suction line - Clean suction line as required.
Air trapped in hydraulic pump - Need to bleed air.
Faulty pump components - Replace or rebuild the pump.
| Electrical Troubleshooting |
Battery will not charge
Electrical cable connections are corroded or loose - Service or tighten cable connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Faulty cell in battery - Battery change required.
Belt is loose or defective - Adjust belt tension or change the belt.
Starter cranks slowly
Low battery voltage - Recharge the battery.
Battery is not holding charge - Service charging system or install new battery.
Disconnected cables or faulty battery terminals - Check wiring connections and replace or clean terminals.
Starter doesn't crank
Battery is low or faulty - Charge or change the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery capacity is low - Charge the battery.
Starter motor failing - Starter should be changed.
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| COMPACT TRACK LOADERS SPECIFICATIONS |