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Mustang 1500R Troubleshooting

The Mustang 1500R skid steer loader driveline system components: Yanmar 4TNV88C-KMS 4-cylinder direct injection naturally aspirated diesel engine with a rated power of 44.5 hp (33 kW), and 1-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 17 gal/min (64.4 l/min). The system relief pressure is 2750 psi (190 bar). The Mustang 1500R is equipped with a radial-lift loader boom, 80K drive chains, and 10x16.5 HD standard tires. The skid steer loader has a maximum lift height of 119" (3325 mm) to hinge pin and dump height of 93.7" (2380 mm). The rated operating capacity is 1500 lbs (680 kg), and tipping load is 3000 lbs (1360 kg).

Engine Troubleshooting

Diesel engine hard to start or doesn't start
There is air in the fuel system - Bleed the system.
Clogged fuel filter - Clean the filter element.
Damaged or dirty injection nozzles - Test injection nozzles and change if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is wrong - Need to adjust valve clearance.
Fuel injection pump malfunction - Change or repair the pump.

Diesel starts and stalls immediately
Air filter is dirty - Clean or change.
Fuel filter plugging - Clean or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Clogged or defective injectors - Replace fuel injectors.
Fuel injection pump is not working correctly - Change pump or rebuild it.

Engine shuts off suddenly while running
Engine is not preheated - Warm up to required temperature.
Fuel filter element is dirty - Clean or change the filter.
Air in fuel tank - Bleed fuel tank.
Clogged or defective injection nozzles - Install a new kit of correctly balanced nozzles.
Improper fuel injection timing - Set up as recommended.

Engine stalls while idling
Low idle speed setting is not correct - Adjust low idle speed.
Fuel injection pump is broken - Replace or repair injection pump.
Clogged or defective injectors - Clean or replace fuel injectors.
Valve clearance is not correct - Correct valve clearance.

Engine power is too low
Air cleaner is dirty - Clean or change.
Faulty fuel injection nozzles - Clean or replace injection nozzles.
Fuel injection pressure is wrong - Test fuel injection pressure and adjust it correctly.
Valve clearance is not correct - Have it adjusted.
Too low idle RPM - Test and adjust.
Fuel hoses or lines are clogged - Clean fuel lines and hoses.
Blown cylinder head gasket - Replace the gasket as required.
Leaking or damaged piston rings - Piston rings replacement required.

Engine overheating
Insufficient coolant - Add coolant and check the components of cooling system.
Insufficient engine oil - Need to add engine oil.
Clogged radiator fins or leaking radiator cap - Clean radiator or change cap.
Fan belt is worn or faulty - The fan belt needs to be replaced.
Engine is under excessive load - Load reducing is recommended.

Low oil pressure
Oil level is low - Fill the crankcase with oil.
Plugged engine oil filter - Service or replace engine oil filter.
Oil grade or viscosity is wrong - Drain and refill with oil of correct grade and viscosity.
Incorrect crankshaft bearing oil clearance - Change bearings.
Oil pump is worn or damaged - Repair or replace.

Engine knocking sound or abnormal noise
Lack of engine oil - Need to add engine oil.
Engine has not warmed up to the recommended temperature - Warm up the engine.
Fuel injection pump timing is not adjusted - Set up as recommended.
Too low idle RPM - Adjust the low idle speed.
Defective fuel injectors - Clean fuel injectors or change it.
Misaligned or faulty connecting rod - Alignment procedure or replacement is required.
Scored or worn pistons - Pistons need to be replaced.

Drive System Troubleshooting

Drive system сan't work in either direction
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Drive chain is worn - Inspect drive chain and replace defective parts.
Relief valve malfunction - Service or change relief valve.
Suction line or hydraulic filter is dirty - Clean suction line or replace hydraulic filter.
Faulty foot or hand controls - Repair or change.
Drive motor or pump is worn - Inspect and change as required.

Reduced power
Clogged hydraulic oil filter - Change or service hydraulic filter.
Relief valve is opened or defective - Close or change relief valve.
Transmission components are worn or defective - Inspect and change faulty parts.
Defective input drive shaft - Change or repair faulty drive shaft.
Air leaks in hydraulic system - Air bleeding is required.

Drive system overheating
Hydraulic fluid level low - Check and refill the hydraulic fluid.
Plugged hydraulic fluid filter - Replace or service hydraulic filter.
Relief valver is broken - Rebuild or install a new relief valve.
Defective drive pump or hydraulic motor - Check and repair if required.
Hydraulic oil cooler is dirty - Clean the cooling fins.
Overloaded drive system - Reduce loading.

Drive system is excessively noisy
Wrong oil viscosity - Drain and refill with correct oil.
Air in hydraulic system - Need to bleed air.
Drive pump or hydraulic motor malfunction - Replace or repair faulty component.
Worn or defective mechanical components of drive system - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is incorrect - Set pressure correctly.
Faulty or improperly adjusted main relief valve - Replace or set up the relief valve.
Hydraulic fluid is dirty - The fluid must be changed.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Lift arm cannot be raised or lowered
Lift controls are damaged - Replace or repair.
Hydraulic pump malfunction - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Repair or replace the valve.
Hydraulic cylinder failure - Replace or repair boom cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket can't tilt
Bucket tilt controls are damaged - Repair or change.
Damaged hydraulic oil pump - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Repair or replace the valve.
Bucket cylinder malfunction - Install a new cylinder or repair it.
Low hydraulic fluid level - Fill up the hydraulic fluid.

Slow bucket or lift arm operation
Defective hydraulic pump - Check hydraulic pump flow and replace pump if necessary.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Low hydraulic oil level - Need to add oil.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust correctly.
Hydraulic system loosing pressure - Correct setting is required.

Bucket or boom movements are jerky
There is air in the hydraulic system - Need to bleed air.
Hydraulic oil filter element clogging - Clean or install new filter.
Contaminated hydraulic oil - Change hydraulic oil.
Scored cylinder tube or rod - Replace defective component.

Hydraulic pump makes excessive noise
Hydraulic leaks or lack of oil - Refill hydraulic oil or repair leaks in system.
Plugged hydraulic filter - Clean or install new filter.
Suction line is clogged - Need to service the suction line.
Air trapped in hydraulic pump - Air bleeding is required.
Faulty pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery does not charge
Electrical cable connections are corroded or loose - Tighten or service cable connections.
Battery terminal clamps are defective - Terminal clamps need to be replaced.
Battery faulty cell - Change the battery.
Belt is damaged or loose - Change belt or adjust belt tension.

Starter motor cranks slow
Low battery output - Low battery charging, charge as required.
Battery is draining quickly - Service charging system or change battery.
Corroded battery terminals or disconnected wires - Connect wiring correctly or install new terminals.

Starter is not working
Battery is low or faulty - Recharge or change battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery voltage is low - Battery is drained, recharge it.
Starter motor failure - Repair or replace starter.