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Home / Wheel Loaders / Kubota Wheel Loaders / Kubota R540

Kubota R540 Troubleshooting

The Kubota R540 wheel loader is powered by 159 cu.in (2.6L) Kubota V2607-CR-E5-WL 4-cylinder liquid-cooled diesel engine with a rated power of 47.9 hp (35.7 kW) at 2400 rpm. The Kubota R540 is equipped with a 2-range hydrostatic transmission, power steering system, wet disc brakes, and 12.5x18 standard tires. The hydraulic system has a pump with fluid flow rate of 14.2 gpm (53.8 lpm). The hydraulic pressure is 2680 psi (185 bar). The wheel loader has a rated operating capacity of 3785 lbs (1720 kg) and tipping load of 7570 lbs (3440 kg). The maximum lift height is 127.2" (3230 mm) to hinge pin, and bucket breakout force is 8160 lbs (3710 kg).

Engine Troubleshooting

Diesel hard to start or doesn't start
There is air in the fuel system - Bleed the system.
Fuel filter element clogging - Change the fiter element.
Fuel injection nozzles are damaged or dirty - Replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Adjust valve clearance according to specifications.
Fuel injection pump is damaged - Replace injection pump or repair it.

Engine stalls after starting
Dirty air cleaner - Clean or change.
Fuel filter plugged - Change or clean the filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Fuel injection pump failure - Replace or repair injection pump.

Diesel shuts off while driving
Engine is cold - Warm up the engine.
Fuel filter element is clogged - Clean the filter or install new filter element.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles are dirty or defective - Change fuel injection nozzles.
Wrong setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stops while idle
Incorrectly set low idle speed - Correct low idle settings.
Fuel injection pump malfunctioning - Change or repair the pump.
Dirty or defective injectors - Clean or replace fuel injectors.
Excessive valve clearance - Have it adjusted.

Low engine power
Air filter is clogged - Clean or change.
Fuel injection nozzles are dirty or defective - Check injection nozzles and replace if required.
Incorrect fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
The valve clearance is incorrect - Adjustment procedure required.
Low idle speed setting is incorrect - Adjust the low idle speed.
Dirt in the fuel hoses or lines - Clean fuel system hoses and lines.
Blown cylinder head gasket - Cylinder-head gasket replacement required.
Piston rings are worn or defective - Install new piston rings.

Engine overheating
Engine has a lack of coolant - Fill radiator to proper level and check components for faults.
Engine oil insufficient - Need to add engine oil.
Dirty radiator fins or faulty radiator cap - Clean radiator or install new cap.
Fan belt is worn or faulty - Replace the fan belt.
Diesel engine is overloaded - Reduce load on the engine.

Oil pressure too low
Oil level is low - Need to add oil.
Oil filter is clogged - Clean or replace engine oil filter element.
Incorrect engine oil Drain crankcase and refill with correct oil.
Incorrect oil clearance in main bearing - Install new bearings.
Oil pump malfunction - Replace as required.

Abnormal engine knocking or noise
Engine oil insufficient - Add oil to the engine crankcase.
Coolant temperature is low - Warm up engine as required.
Improper setting of fuel injection pump timing - Set up as recommended.
Incorrectly set low idle speed - Adjust low idling as recommended.
Dirty or defective injectors - Clean or replace fuel injectors.
Connecting rod is defective or not aligned - Connecting rod must be aligned or replaced.
Worn or scored pistons - Pistons need to be replaced.

Hydrostatic Transmission Troubleshooting

HST transmission noises
Insufficient oil level or contaminated oil - Change transmission oil or top up to proper level.
Worn or out of adjustment speed control linkage - Adjust or repair linkage.
Relief valve failure - Replace relief valve.
Transmission is under excessive load - Reduce transmission load.
Transmission components are damaged or worn - After disassembly and inspection, replace defective components.

Loss of power
Lack of transmission fluid - Check and refill the transmission fluid.
Relief valve is stuck - Replace valve as required.
Bent or unadjusted speed control pedal linkage - Repair or adjust linkage.

Transmission fluid is too hot
Transmission oil level is low - Fill the transmission housing to proper oil level.
Transmission oil filter is dirty - Clean or replace the transmission filter.
Cooling components are plugged or defective - Check all cooling components and clean or replace if required.
Transmission overload - Reduce the load is required.

Transmission oil leakage
Seals or gaskets are worn - Seals and gaskets need to be replaced.
Internal transmission housing pressure is too high - Change defective components.
Plugged transmission fluid return tube - Service or replace return tube.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Adjust it correctly.
Misadjusted or defective main relief valve - Adjust relief valve or change if required.
Hydraulic fluid is contaminated - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Check and refill the hydraulic fluid.
Hydraulic pump is faulty - Replace or repair pump if necessary.

Boom can't lift or drop
Lift controls are defective - Change or repair.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or replace hydraulic valve.
Defective hydraulic cylinder - Change or repair lift cylinder.
Hydraulic oil level low - Checking hydraulic oil level and add if necessary.

Bucket tilt does not work
Damaged bucket controls - Repair or change.
Defective hydraulic pump - Repair or replace pump if necessary.
Damaged hydraulic control valve - Change or repair hydraulic valve.
Damaged bucket cylinder - Repair or change cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Bucket or lift arm moves slowly
Hydraulic pump is worn - Check the pump performance and replace it if required.
Hydraulic cylinder leaking - Install new cylinder seals.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.
Damaged or incorrect adjusted hydraulic control valve - Set correctly or repair.
Hydraulic pressure loss - Set pressure correctly.

Lift arm or bucket is jerky
Air leaks in hydraulic system - Need to bleed air.
Clogged hydraulic oil filter element - Service or change the hydraulic filter.
Dirty hydraulic oil - Change hydraulic oil.
Cylinder rod or tube is scratched - Change damaged component.

Hydraulic pump makes excessive noise
Hydraulic leakage or low oil level - Correct hydraulic leaks or top up oil as needed.
Clogged hydraulic filter - Service or change hydraulic filter.
Dirty suction line - Need to service the suction line.
Air trapped in hydraulic pump - Bleed air from hydraulics.
Pump components are faulty - Rebuild or install new pump.

Electrical Troubleshooting

Battery does not charge
Electrical wire connections are loose or corroded - Tighten or service connections.
Battery terminal clamps are faulty - Change terminal clamps.
Worn-out battery - Battery replacement required.
Damaged or loose belt - Change belt or adjust belt tension.

Starter cranks slow
Low battery power - Recharge the battery.
Battery won’t hold charge - Battery needs service or replacement.
Disconnected cables or faulty battery terminals - Connect cables correctly or replace terminals.

Starter does not work
Battery is low or faulty - Recharge or change battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery power - Recharge the battery.
Defective starter motor - Repair or change starter.

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WHEEL LOADERS SPECIFICATIONS

Caterpillar