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Mustang 2109 Troubleshooting

The Mustang 2109 skid steer loader is powered by Perkins 1104C-E44T 4-cylinder direct injection turbocharged liquid-cooled diesel engine with a rated power of 115 hp (86 kW) at 2400 rpm. The Mustang 2109 is equipped with a radial-lift boom, one-speed or two-speed hydrostatic transmission, 100HK drive chains, and 14x17.5 tires. The hydraulic system has a pump with fluid flow rate of 29 gpm (110 lpm) or 40 gpm (151.5 lpm). The hydraulic pressure is 3300 psi (228 bar). The skid steer loader has a rated operating capacity of 3675 lbs (1724 kg) and tipping load of 7350 lbs (3335 kg). The lift height is 142" (3605 mm) to hinge pin, and dump height is 107" (2720 mm).

Engine Troubleshooting

Engine starts up hard or won't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter plugged - Clean the filter or install new filter element.
Clogged or burnt injection nozzle - Test injection nozzles and change if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Have it adjusted.
Fuel injection pump is not operating properly - Rebuild or change fuel pump.

Diesel starts but immediately shuts off
Clogged air cleaner - Clean or replace element.
Clogged fuel filter - Change or clean the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Clogged or defective injectors - Replace or clean fuel injectors.
Damaged fuel injection pump - Change or repair the pump.

Engine shuts off while running
Low coolant temperature - Engine is not warmed up to the required temperature.
Clogged fuel filter - Change filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Damaged or dirty injection nozzles - Service or change injection nozzles.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.

Engine stalls when idling
Too low idle RPM - Adjust low idle speed.
Fuel injection pump is broken - Replace or rebuild injection pump.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Valve clearance is out of adjustment - Adjust to proper valve clearance.

Engine power loss
Clogged air cleaner - Clean or replace air cleaner element.
Clogged or defective injection nozzles - Clean or replace injection nozzles.
Uneven fuel injection pressure - Adjust to proper pressure.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Low idle speed setting is not correct - Normalize low idle speed.
Dirty fuel hoses or lines - Service fuel lines and hoses.
Damaged cylinder-head gasket - Replace the gasket as required.
Piston rings are damaged or leaking - Replace piston rings.

Engine overheating
Lack of coolant in cooling system - Add coolant and check the components of cooling system.
Lack of engine oil - Check oil level and add oil as required.
Radiator core is clogged or radiator cap is leaking - Install new cap or clean radiator.
Loose or defective fan belt - Belt change is required.
Diesel engine is overloaded - Load reducing required.

Oil pressure is insufficient
Engine oil level low - Fill the crankcase with oil.
Dirty oil filter - Clean or change engine oil filter.
Wrong oil viscosity - Use oil of correct viscosity.
Incorrect oil clearance in main bearing - Bearings need to be reinstalled.
Worn oil pump - Check and replace if necessary.

Engine noise or knocking
Engine oil level is insufficient - Need to add engine oil.
Engine not warmed up - Normalize the temperature by warming up the engine.
Fuel injection pump timing is wrong - Set up as recommended.
Incorrectly set low idle speed - Correct low idle settings.
Dirty or defective injectors - Replace fuel injectors.
Connecting rod is worn or misaligned - Need to align or replace the connecting rod.
Scored or worn pistons - Replace the pistons.

Drive System Troubleshooting

Drive system сan't work in either direction
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Drive chain is worn - Inspect drive chain and replace defective parts.
Worn or defective relief valve - Change or repair relief valve.
Hydraulic filter or suction line is dirty - Service suction line or replace hydraulic filter.
Hand or foot controls malfunction - Inspect and repair if necessary.
Defective drive pump or motor - Inspect and change as required.

Low power
Hydraulic oil filter is dirty - Replace hydraulic filter.
Relief valve is defective or opened - Close or replace relief valve.
Transmission parts are defective or worn - Inspect and change faulty parts.
Input drive shaft is stuck - Replace drive shaft.
Air in hydraulic system - Need to bleed air.

Overheated drive system
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Hydraulic fluid filter is clogged - Change hydraulic filter.
Relief valve worn or defective - Change or repair defective relief valve.
Damaged drive pump or hydraulic motor - Check and repair if required.
Oil cooler is clogged - Cooling fins should be cleaned.
Drive system overload - Reduce loading.

Drive system makes excessive noise
Incorrect oil viscosity - Drain and refill with proper oil.
Air in the hydraulic system - Air bleeding is required.
Damaged drive pump or hydraulic motor - Repair or replace faulty component.
Mechanical components of drive system are defective or worn - Inspect drive system and replace faulty parts.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is incorrect - Adjust it correctly.
Main relief valve improper adjustment or failure - Adjust or change relief valve.
Hydraulic oil is contaminated - Hydraulic oil change required.
Lack of hydraulic oil - Fill the hydraulic system with oil.
Defective hydraulic pump - Repair or install new hydraulic pump.

Boom can't lift or drop
Lift controls are defective - Repair or replace.
Defective hydraulic pump - Repair or change pump if required.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Hydraulic cylinder malfunction - Repair or replace hydraulic cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Bucket fails to tilt
Bucket tilt controls are damaged - Repair or change.
Hydraulic pump not working - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Repair or change the valve.
Bucket cylinder failure - Install a new cylinder or repair it.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.

Bucket or lift arm moves slowly
Faulty hydraulic oil pump - Test the pump flow rate and change pump if required.
Hydraulic cylinder leaking - Install new cylinder seals.
Hydraulic oil level low - Need to add oil.
Hydraulic control valve is defective or set improper - Set properly or repair.
Hydraulic pressure loss - Set pressure correctly.

Lift arm or bucket is jerky
Air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is clogged - Replace or clean the filter.
Hydraulic fluid is contaminated - The fluid must be changed.
Cylinder rod or tube is scuffed - Replace failed component.

Excessive hydraulic pump noise
Hydraulic leakage or low oil level - Refill hydraulic oil or repair leaks in system.
Plugged hydraulic filter - Clean or change the filter.
Clogged suction line - Suction line must be serviced.
Pump is sucking air - Air bleeding is required.
Damaged pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose electrical wire connections - Clean or tighten connections.
Defective battery terminal clamps - Install new terminal clamps.
Battery bad cell - Battery change required.
Belt is damaged or loose - Change belt or adjust belt tension.

Starter cranks slow
Low battery power - Recharge the battery.
Battery drains quickly - Service charging system or replace battery.
Bad battery terminals or disconnected wiring - Connect cables correctly or replace terminals.

Starter motor is not working
Battery is discharged or worn - Need to charge or replace the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery output - Low battery charging, charge as required.
Starter motor failure - Repair or change starter.