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Home / Wheel Loaders / Bobcat Wheel Loaders / Bobcat AL440

Bobcat AL440 Troubleshooting

The Bobcat AL440 articulated wheel loader is powered by 203.2 cu.in (3.1L) Kubota V3300-DI-T 4-cylinder direct injection turbocharged diesel engine with a rated power of 82.1 hp (61.2 kW) at 2200 rpm. The Bobcat AL440 is equipped with a two-range hydrostatic transmission, power steering system, hydraulic drum brakes, and 365/80R20 tires. The hydraulic system has a pump with fluid flow rate of 19 gpm (72 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 4290 lbs (1950 kg) and tipping load of 8580 lbs (3900 kg). The max lift height is 132.6" (3370 mm) to hinge pin, and breakout force is 13680 lbs (6220 kg).

Engine Troubleshooting

Engine starts up hard or won't start
Air in the fuel lines - Bleed the fuel lines.
Dirty fuel filter - Service the filter.
Fuel injection nozzles are clogged or faulty - Clean or replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is out of adjustment - Check and adjust.
Fuel injection pump damage - Repair or change injection pump.

Engine starts but then stops
Air cleaner is clogged - Service or replace air cleaner.
Fuel filter element is clogged - Replace the filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Damaged or clogged injectors - Test and replace fuel injectors if necessary.
Fuel injection pump is faulty - Repair or change injection pump.

Diesel shuts off while driving
Low coolant temperature - Warm up to required temperature.
Fuel filter element is clogged - Clean or replace the filter.
There is air in the fuel system - Bleed the system.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Fuel injection pump timing is not adjusted - Set the fuel pump timing correctly.

Engine stalling at idle
Improperly adjusted low idle speed - Adjust as required.
Fuel injection pump failure - Repair or install new pump.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Valve clearance is wrong - Correct valve clearance needs to be set.

Engine power is insufficient
Clogged air cleaner - Clean or change.
Clogged or defective injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is incorrect - Check the fuel injection pressure and adjust if necessary.
Valve clearance is not correct - Need to adjust valve clearance.
Wrong adjustment of low idle speed - Need to adjust idle speed.
Clogged fuel hoses or lines - Clean fuel system hoses and lines.
Cylinder-head gasket is broken - Install a new gasket.
Damaged or leaking piston rings - Replace piston rings.

Engine overheats
Low coolant level - Fill the cooling system and check components for leaks or other faults.
Engine oil insufficient - Need to add engine oil.
Dirty radiator core or faulty radiator cap - Clean radiator or replace cap.
Fan belt slipping or worn - The fan belt needs to be replaced.
Engine is under excessive load - Load reducing required.

Insufficient oil pressure
Not enough oil in the engine - Add oil to the engine crankcase.
Plugged engine oil filter - Replace or clean engine oil filter element.
Oil grade or viscosity is wrong - Use oil of correct viscosity.
Incorrect oil clearance in main bearing - Bearing replacement required.
Oil pump is worn or damaged - Replace as required.

Abnormal engine noise or knocking
Not enough engine oil - Need to add engine oil.
Coolant temperature is low - Normalize the temperature by warming up the engine.
Wrong setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Too low idle RPM - Normalize low idle speed.
Defective fuel injectors - Change or clean fuel injectors.
Connecting rod is worn or misaligned - Connecting rod must be aligned or replaced.
Piston wear or scoring - Pistons need to be replaced.

Hydrostatic Transmission Troubleshooting

HST transmission is excessively noisy
Low transmission oil level or contaminated oil - Add oil to the correct level or fill the transmission with fresh oil.
Worn or unadjusted speed control linkage - Replace or adjust linkage.
Stuck relief valve - Change relief valve.
Transmission overloaded - Reduce loading.
Transmission components are damaged or worn - After disassembly and inspection, replace defective components.

Power is insufficient
Transmission oil level is low - Add oil to the transmission housing.
Stuck relief valve - Replace relief valve.
Bent or unadjusted speed control pedal linkage - Change or adjust linkage.

Transmission fluid over heats
Transmission oil insufficient - Fill the transmission housing with oil.
Transmission oil filter is clogged - Service or change transmission oil filter.
Damaged or clogged cooling components - Inspect all cooling components and replace or repair if necessary.
Excessive transmission load - The load should be reduced.

Transmission oil leaking
Seals or gaskets are broken - Install new components.
Internal transmission housing pressure is too high - Check transmission parts for damage or wear and replace if required.
Oil return tube is plugged - Clean or replace the tube.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is incorrect - Correct setting is required.
Main relief valve improper adjustment or failure - Replace or set up the relief valve.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Lack of hydraulic oil - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Lift arm cannot be raised or lowered
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump is broken - Replace or repair pump if necessary.
Damaged hydraulic control valve - Repair or change hydraulic valve.
Faulty hydraulic cylinder - Replace or repair boom cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Bucket does not function
Bucket tilt controls are damaged - Inspect and repair if necessary.
Hydraulic pump failure - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Repair or change the valve.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Bucket or lift arm is working slowly
Faulty hydraulic oil pump - Test pump performance and replace pump if necessary.
Hydraulic cylinder oil leakage - Install new cylinder seals.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Damaged or incorrect adjusted hydraulic control valve - Set properly or repair.
Hydraulic pressure is low - Correct adjustment is required.

Lift arm or bucket is working jerkily
Air trapped in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter element is clogged - Clean or replace the filter.
Hydraulic oil contamination - The oil must be changed.
Cylinder tube or rod is scored - Change worn component.

Excessive hydraulic pump noise
Lack of oil or hydraulic leakage - Repair hydraulic leaks or add oil as required.
Hydraulic filter is clogged - Clean or install new filter.
Plugged suction line - Need to service the suction line.
Air in hydraulic pump - Remove air from hydraulics.
Pump components are worn out - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Corroded or loose electrical wire connections - Tighten or clean electrical wiring connections.
Battery terminal clamps are defective - Change terminal clamps.
Defective battery - Battery change required.
Worn or loose belt - Replace belt or adjust belt tension.

Starter cranks slow
Low battery output voltage - Battery needs to be recharged.
Battery runs out quickly - Service or change the battery.
Disconnected cables or faulty battery terminals - Check cables and clean or change terminals.

Starter does not work
Battery is drained or worn - Need to charge or replace the battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery capacity is low - Charge the battery.
Starter motor failing - Change or repair starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders