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Mustang 1900R Troubleshooting

The Mustang 1900R skid steer loader driveline system components: a 202.5 cu.in (3.3L) Yanmar 4TNV98C-NMS 4-cylinder direct injection diesel engine with a rated power of 68.4 hp (51.1 kW), and 1-speed or 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 18.5 gal/min (70 l/min). The system pressure is 2750 psi (190 bar). The Mustang 1900R is equipped with a radial-lift boom, 80K drive chains, and 10x16.5 HD tires. The skid steer loader has a max lift height of 120.5" (3060 mm) to hinge pin and dump height of 91" (2310 mm). The rated operating capacity is 1900 lbs (862 kg), and tipping load is 3800 lbs (1725 kg).

Engine Troubleshooting

Diesel hard to start or doesn't start
Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Replace filter element.
Dirty or faulty injection nozzles - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Need to adjust valve clearance.
Fuel injection pump malfunction - Install a new fuel pump or repair.

Engine starts and immediately shuts off
Dirty air cleaner - Clean or change cleaner.
Clogged fuel filter - Replace the filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Defective or clogged fuel injectors - Replace fuel injectors.
Fuel injection pump is defective - Replace injection pump or repair it.

Engine shuts off suddenly during operation
Low coolant temperature - Warm up the engine.
Fuel filter element clogging - Clean or replace the filter.
Air in the fuel lines - Bleed the fuel lines.
Dirty or damaged injection nozzles - Inspect nozzles and replace if necessary.
Fuel injection pump timing is not adjusted - Set up as recommended.

Engine stalls at idle
Improperly adjusted low idle speed - Test and adjust.
Fuel injection pump is not working correctly - Repair or install new pump.
Defective fuel injectors - Clean or replace fuel injectors.
Valve clearance is out of adjustment - Correct valve clearance.

Engine loses power
Air filter is dirty - Service or replace the air filter.
Clogged injection nozzle - Clean or replace injection nozzles.
Improper fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve clearance is not correct - Have it adjusted.
Incorrectly set low idle speed - Correct low idle settings.
Fuel hoses or lines clogging - Fuel lines and hoses need to be cleaned.
Cylinder head gasket is blown - Gasket should be replaced.
Defective or worn piston rings - Replace piston rings.

Engine overheating
Not enough coolant - Refill to the correct level and inspect system for leaks.
Engine oil insufficient - Fill up the oil to required level.
Defective radiator cap or clogged radiator core - Clean radiator or replace cap.
Damaged or worn fan belt - Fan belt must be replaced.
Diesel engine overloaded - Load reducing is recommended.

Oil pressure is insufficient
Engine oil insufficient - Need to add oil.
Plugged engine oil filter - Change or service engine oil filter.
Wrong oil viscosity - Use the specified type of engine oil.
Excessive crankshaft bearing oil clearance - Bearings need to be reinstalled.
Oil pump is damaged - Repair or change.

Engine noises or knocks
Low engine oil level - Checking oil level and add if necessary.
Engine has not warmed up to the recommended temperature - Warm up engine as required.
Timing of fuel injection pump is incorrect - Set up as recommended.
Incorrect low idle setting - Adjust low idle speed.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Connecting rod is not aligned or worn - Need to replace or align the connecting rod.
Worn or scored pistons - Install new pistons.

Drive System Troubleshooting

Machine will not move in either direction or one direction
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.
Drive chain malfunction - Inspect drive chain and replace faulty components.
Relief valve is defective - Service or change relief valve.
Suction line or hydraulic filter is clogged - Check, clean, or change if necessary.
Foot or hand controls are defective - Repair or replace.
Drive pump or motor is damaged - Change or repair faulty component.

Lack of power
Hydraulic oil filter is clogged - Replace or clean hydraulic filter.
Defective or open relief valve - Close or change relief valve.
Transmission components are worn or defective - Inspect and change defective parts.
Stuck input drive shaft - Service or change faulty drive shaft.
Hydraulic system is leaking air - Bleed air from hydraulic system.

Drive system is overheated
Hydraulic oil is insufficient - Need to add oil.
Hydraulic fluid filter is plugged - Replace hydraulic filter.
Relief valver is broken - Change or repair defective relief valve.
Worn hydraulic motor or drive pump - Repair or change faulty component.
Plugged hydraulic oil cooler - Cooling fins need to be cleaned.
Overloaded drive system - Load should be reduced.

Excessive noise
Wrong oil viscosity - Drain and refill with proper oil.
Hydraulic system is leaking air - Bleed air from hydraulic system.
Drive pump or hydraulic motor malfunction - Check and repair if required.
Mechanical parts of drive system are defective or worn - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is not adjusted correctly - Hydraulic pressure must be set correctly.
Main relief valve failure or improper setting - Replace or set up the relief valve.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Not enough hydraulic fluid in the system - Add fluid to the hydraulic system.
Hydraulic pump is defective - Change or repair hydraulic pump if required.

Lift arm cannot be raised or lowered
Lift controls malfunction - Repair or change.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve is defective - Repair or change hydraulic valve.
Hydraulic cylinder is defective - Repair or install a new lift cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Bucket can't tilt
Bucket tilt controls malfunction - Change or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Defective hydraulic control valve - Install a new hydraulic valve or repair it.
Defective bucket cylinder - Repair or replace cylinder.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Boom or bucket moves slowly
Faulty hydraulic oil pump - Test pump performance and replace pump if necessary.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is not set properly or defective - Repair or set correctly.
Hydraulic pressure is low - Adjust it correctly.

Lift arm or bucket is jerky
Air leaks in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is clogged - Clean or replace the filter.
Hydraulic oil contamination - Fill up with fresh hydraulic oil.
Scored cylinder tube or rod - Replace defective component.

Hydraulic pump is excessively noisy
Low oil level or hydraulic leaks - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter clogging - Clean or replace the filter.
Suction line clogging - Clean suction line as required.
Pump is sucking air - Remove air from hydraulics.
Pump parts are worn out - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose wire connections - Clean or tighten wiring connections.
Electrical terminal connectors are faulty - Install new terminal connectors.
Worn-out battery - Use a new battery.
Damaged or loose belt - Belt needs to be adjusted or replaced.

Starter cranks slowly
Low battery capacity - Low battery charging, charge as required.
Battery drains quickly - Service battery or change it.
Bad terminals or disconnected battery cables - Check cable connections and replace or service terminals.

Starter doesn't crank
Battery is drained or defective - Charge or change the battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Low battery voltage - Battery is drained, recharge it.
Defective starter motor - Replace or repair starter.