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Case 40XT Troubleshooting

The Case 40XT skid steer loader is powered by 239 cu.in (3.9L) Case 4-390 four-cylinder direct injection naturally aspirated diesel engine with a rated power of 60 hp (44.7 kW) at 2200 rpm. The Case 40XT is equipped with a single-speed hydrostatic transmission, single-reduction chain drive, and 10x16.5 or 13x16.5 tires. The open center hydraulic system has a gear pump with fluid flow rate of 19.1 gpm (72.2 lpm). The hydraulic pressure is 3000 psi (207 bar). The skid steer loader has a rated operating capacity of 1500 lbs (680 kg) and tipping load of 3000 lbs (1360 kg). The boom lifting force is 3788 lbs (1720 kg), and bucket breakout force is 3974 lbs (1800 kg).

Engine Troubleshooting

Engine starts hard or doesn't start
Air in the fuel lines - Bleed the fuel lines.
Fuel filter element clogging - Change filter element.
Dirty or damaged injection nozzles - Check injection nozzles and replace if required.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is wrong - Adjust valve clearance.
Fuel injection pump is not working correctly - Replace or repair injection pump.

Engine starts but stalls suddenly
Plugged air filter - Clean or replace element.
Dirty fuel filter - Clean or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Defective fuel injection pump - Install a new pump or rebuild.

Engine stalls after running
Engine is cold - Warm up engine as required.
Fuel filter element is dirty - Service or replace the filter.
Air in fuel system - Bleed fuel system.
Damaged or dirty injection nozzles - Check and replace nozzles if required.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.

Engine stops while idling
Incorrect low idle setting - Need to adjust idle speed.
Damaged fuel injection pump - Repair or install new pump.
Damaged or clogged injectors - Replace or clean fuel injectors.
Valve clearance is wrong - Correct valve clearance.

Engine power is too low
Clogged air cleaner - Service or replace air cleaner.
Fuel injection nozzles are dirty or defective - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Incorrect valve clearance - Check and adjust as required.
Incorrect low idle speed adjustment - Correct low idle adjustment.
Dirt in the fuel lines or hoses - Clean fuel hoses and lines.
Cylinder head gasket is damaged - Install a new gasket.
Piston rings are damaged or leaking - Piston rings need to be replaced.

Engine overheats
Lack of coolant in cooling system - Fill radiator to proper level and check components for faults.
Engine oil insufficient - Check oil level and add oil as required.
Dirty radiator fins or defective radiator cap - Change cap or clean radiator.
Excessive wear of the fan belt - Fan belt must be replaced.
Diesel engine is overloaded - Load reducing required.

Oil pressure is insufficient
Lack of oil - Check and refill the oil.
Clogged oil filter element - Service or replace engine oil filter.
Incorrect oil viscosity - Use correct viscosity oil.
Main bearing oil clearance is excessive - Bearing replacement required.
Oil pump failure - Repair or replace.

Engine noise or knocking
Not enough engine oil - Check and refill engine oil.
Low coolant temperature - Warm up the engine as required.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Wrong adjustment of low idle speed - Adjust low idle speed.
Clogged or defective injectors - Test and replace fuel injectors if necessary.
Connecting rod is not aligned or defective - Align or change connecting rod.
Piston wear or scoring - Have pistons replaced.

Drive System Troubleshooting

Drive system will not operate in either direction
Insufficient hydraulic fluid - Add fluid as required.
Drive chain is worn - Inspect drive chain and replace defective components.
Input drive shaft is not working properly - Replace or service the drive shaft.
Defective relief valve - Rebuild or install a new relief valve.
Hydraulic filter or suction line is plugged - Service suction line or replace hydraulic filter.
Defective foot or hand controls - Repair or replace.
Worn drive motor or pump - Replace or repair faulty component.

Low power
Hydraulic oil filter is clogged - Check, clean, or change as necessary.
Opened or defective relief valve - Change or close relief valve.
Transmission parts are defective or worn - Check and replace defective components.
Input drive shaft is damaged - Repair or replace faulty drive shaft.
Hydraulic system is leaking air - Air bleeding is required.

Drive system keeps overheating
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Hydraulic fluid filter is clogged - Change hydraulic filter.
Defective relief valve - Repair or replace.
Hydraulic motor or drive pump is worn - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Drive system overload - Reduce loading.

Drive system makes excessive noise
Oil viscosity is incorrect - Use proper oil viscosity.
Air in the hydraulic system - Bleed air from system.
Defective drive pump or hydraulic motor - Repair or replace faulty component.
Worn or defective mechanical parts of drive system - Check the components for defect or damage and change if necessary.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is incorrect - Correct adjustment is required.
Main relief valve is defective or unadjusted - Set up or change the relief valve.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Not enough hydraulic oil in the system - Check oil level and add hydraulic oil as required.
Hydraulic pump is faulty - Install new pump or repair it.

Boom won't lower or raise
Lift controls failure - Replace or repair.
Hydraulic pump is broken - Install new pump or repair it.
Hydraulic control valve malfunction - Install a new hydraulic valve or repair it.
Hydraulic cylinder failure - Repair or change hydraulic cylinder.
Hydraulic fluid is insufficient - Add fluid as required.

Bucket does not tilt
Bucket tilt controls malfunction - Repair or replace.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Hydraulic bucket cylinder not working - Repair or change cylinder.
Hydraulic oil level low - Checking hydraulic oil level and add if necessary.

Slow boom or bucket operation
Faulty hydraulic oil pump - Check the pump capacity and replace pump if required.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is unadjusted or worn - Repair or adjust correctly.
Low hydraulic pressure - Adjust pressure correctly.

Lift arm or bucket is working jerkily
Air in the hydraulic system - Air bleeding is required.
Hydraulic oil filter element is dirty - Change or clean oil filter.
Hydraulic fluid is contaminated - Change hydraulic fluid.
Cylinder rod or tube is scratched - Replace failed component.

Hydraulic pump is excessively noisy
Not enough oil or hydraulic system leaking - Repair hydraulic leaks or add oil as required.
Plugged hydraulic filter - Service or replace hydraulic filter.
Plugged suction line - Service the suction line.
Pump sucks air - Air bleeding is required.
Pump parts are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are corroded or loose - Tighten or service connections.
Electrical terminal connectors are faulty - Replace terminal connectors.
Defective battery - Use a new battery.
Worn or loose belt - Adjust belt tension or install a new belt.

Starter turns slowly
Low battery capacity - Recharge the battery.
Battery runs out quickly - Service charging system or change battery.
Disconnected battery cables or bad terminals - Check wiring and clean or replace terminals.

Starter is not cranking
Battery is drained or worn - Battery needs to be recharged or replaced.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery voltage - Recharge the battery.
Starter motor is faulty - Starter should be replaced.