Troubleshooting


  Engine
  Hydraulic & final drive
  Electrical
  Controls

 

  Engine
 
  • I have difficulties starting my engine in my loader, what could be the cause?
     
  • I have fuel mixed into my lubricant oil, why?
     
  • I have high oil pressure, what causes this?
     
  • I have low oil pressure, what causes this?
     
  • I have water mixed into my lubricant oil, why?
     
  • My battery quickly discharges, what can cause this?
     
  • My engine does not develop full power, what could be the cause of this?
     
  • My engine keeps overheating, why?
     
  • My engine revolution is not smooth, what should I look for?
     
  • My engine revolution is not smooth, what should I look for?
     
  • My engine starts and stops, what could be the cause?
     
  • My engine will not start, what should I check for?
     
  • My loader uses excessive lubricant oil, what causes this?
     
  • My starter does not turn over, what could be the problem?
     
  • The exhaust coming out of my loader is either white or blue, what might be the cause?

      Hydraulic & final drive
     
  • I have no drive on one side, what should I look for?
     
  • I have no hydraulic power (there is no flow from the gear pump). What Should I do?
     
  • I have no hydraulic power, but I have full flow from gear pump. What Should I do?
     
  • My final drive is noisy, what could be causing that?
     
  • My hydraulic cylinders will not support a load, they "leak" down, what causes this?
     
  • My wheel studs keep shearing off, why is this happening and what can I do to prevent this from happening?
     
  • What can cause the hydraulic oil to overheat?
     
  • What causes lubrication oil leaking through the filler breather cap?
     
  • Why do my wheel studs keep stripping?
     
  • Why does my boom rise slowly at full rpm?
     
  • Why does my hydraulic drive act erratically?

      Electrical
     
  • My boom controls seem to be stiff, what can I do to loosen it?
     
  • My brake will not hold, what can cause this?
     
  • The aux (electric) is not functioning. What should I do?
     
  • When I turn my key, I have no power.

      Controls
     
  • My auxiliary is inoperative (solenoid control type), what can I do?
     
  • My boom controls are inoperative, what can cause this to happen?
     
  • My boom operation is slow, what can I do to correct this?
     
  • My loader creeps and will not center, what causes this and how can I fix it?
     
  • My loader is not tracking straight, what should I look for?
     
  • The brakes on my loader won’t release. What can I do to fix this?
     
  • What causes the steering to be "jerky" or "jumpy"?

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    Engine

      Q: I have difficulties starting my engine in my loader, what could be the cause?
      A: Here are a few things you can check:
    • Low cranking speed - Check the charge in the battery. Check starter. Repair or replace
    • Incorrect pump timing - Check the pump timing
    • Restricted fuel filter - Check and flush or replace the fuel filter clear.
    • Contaminated fuel - Check for water in the fuel
    • Low compression - Check the engine compression
    • Air in system - Check for air leaks on the suction side of the system

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: I have fuel mixed into my lubricant oil, why?
      A: Here are a few possible explanations to this:
    • Injection pump’s plunger worn - Replace pump element or pump
    • Injection pump broken - Replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: I have high oil pressure, what causes this?
      A: Here are a few possible explanations to this:
    • Relief valve defective – Replace
    • Engine oil insufficient - Replenish

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: I have low oil pressure, what causes this?
      A: Here are a few possible explanations to this:
    • Engine oil insufficient – Replenish
    • Oil strainer clogged – Clean
    • Relief valve stuck with dirt – Clean
    • Relief valve spring weakened or broken – Replace
    • Excessive oil clearance of crankshaft bearing – Replace
    • Excessive oil clearance of crank pin bearing – Replace
    • Excessive oil clearance of rocker arm bearing – Replace
    • Oil passage clogged – Clean
    • Oil pump defective – Replace
    • Different type of oil - Use the specified oil type

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: I have water mixed into my lubricant oil, why?
      A: Here are a few possible explanations to this:
    • Head gasket defective – Replace
    • Cylinder block or cylinder head flawed - Replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My battery quickly discharges, what can cause this?
      A: Here are a few possible explanations to this:
    • Battery electrolyte insufficient - Replenish distilled water
    • Fan belt slips - Adjust belt tension or change
    • Wiring disconnected – Connect
    • Rectifier defective - Test, replace
    • Alternator defective - Test, repair, replace
    • Battery defective - Test, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine does not develop full power, what could be the cause of this?
      A: Here are a few possible explanations to this:
    • Unsuitable fuel used - Use the specified fuel
    • Clogged air cleaner - Clean, replace
    • Fuel line, filter obstruction - Test, repair, replace
    • Incorrect injection timing – Adjust
    • Engine’s moving parts seem to be seizing - Repair or replace
    • Uneven fuel injection - Repair or replace injection pump
    • Deficient nozzle injection - Repair or replace nozzle
    • Compression leak - Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine keeps overheating, why?
      A: Here are a few possible explanations to this:
    • Fan belt broken or elongated - Change or adjust
    • Cooling water insufficient - Check for leaks, replenish
    • Radiator net and radiator fin clogged with dust – Clean
    • Inside of radiator corroded - Clean or replace
    • Cooling water flow route corroded - Clean or replace
    • Radiator cap defective – Replace
    • Overload running - Loosen the load
    • Head gasket defective – Replace
    • Restricted exhaust - Check
    • Incorrect injection timing – Adjust
    • Water pump failure - Test, repair, replace
    • Thermostat failure - Test, replace
    • Low on engine oil - Check, replenish if necessary
    • Collapsed hose - Replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine revolution is not smooth, what should I look for?
      A: Here are a few things you can check:
    • Fuel filter clogged or dirty - Clean or change
    • Air cleaner clogged - Clean or change
    • Fuel leak due to loose injection pipe retaining nut - Tighten nut
    • Injection pump malfunctioning - Repair or replace
    • Incorrect nozzle opening pressure – Adjust
    • Injection nozzle stuck or clogged - Repair or replace
    • Fuel overflow pipe clogged – Clean
    • Governor malfunctioning - Repair

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine revolution is not smooth, what should I look for?
      A: Here are a few things you can check:
    • Fuel filter clogged or dirty - Clean or change
    • Air cleaner clogged - Clean or change
    • Fuel leak due to loose injection pipe retaining nut - Tighten nut
    • Injection pump malfunctioning - Repair or replace
    • Incorrect nozzle opening pressure – Adjust
    • Injection nozzle stuck or clogged - Repair or replace
    • Fuel overflow pipe clogged – Clean
    • Governor malfunctioning - Repair

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine starts and stops, what could be the cause?
      A: Here are a few things you can check:
    • Fuel starvation - Check and flush clean restricted fuel lines or fuel filter
    • Contaminated fuel - Check for water in the fuel
    • Restricted air intake - Check for restrictions in the air intake
    • Engine overheating - Check cooling system
    • Air in system - Check for air leaks on the suction side of the system

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My engine will not start, what should I check for?
      A: Here are a few things you can check:
    • Low fuel - Replenish fuel
    • Air in the fuel - Vent air
    • Water in the fuel - Change fuel and repair or replace the system
    • Fuel pipe clogged – Clean
    • Fuel filter clogged - Clean or change
    • Air filter dirty - Clean or replace
    • Excessively high viscosity of fuel or engine oil at low temperature - Use the specified fuel or engine oil
    • Fuel with low octane number - Use the specified fuel
    • Fuel leak due to loose injection pipe retaining nut - Tighten nut
    • Incorrect injection timing – Adjust
    • Fuel cam shaft worn - Replace
    • Injection nozzle clogged – Clean
    • Injection pump malfunctioning - Repair or replace
    • Seizure of crankshaft, camshaft, piston, cylinder liner or bearing - Repair or replace
    • Compression leak from cylinder - Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder
    • Improper valve timing - Correct or replace timing gear
    • Piston ring and liner worn – Replace
    • Excessive valve clearance – Adjust
    • Faulty starter switch - Test, repair or replace.
    • Low or weak battery - Charge, test, replace.
    • Irregular or faulty fuel supply - Test fuel pump. Repair or replace
    • Glow plugs not heating - Test, repair, replace
    • Starter malfunctioning - Repair or replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My loader uses excessive lubricant oil, what causes this?
      A: Here are a few possible explanations to this:
    • Piston rings gap facing the same direction - Shift gap direction
    • Oil ring worn or stuck – Replace
    • Piston ring groove worn – Replace
    • Valve stem and guide worn – Replace
    • Crankshaft bearing and crank pin bearing worn – Replace
    • Engine oil level too high - Drain to proper level
    • Leaking cylinder head gasket – Replace
    • Clogged return hole of oil ring - Inspect, repair, replace
    • External oil leak - Repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My starter does not turn over, what could be the problem?
      A: Here are a few things you can check:
    • Battery discharged - Charge, test, replace.
    • Key switch malfunctioning - Test, replace
    • Wiring disconnected - Connect

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: The exhaust coming out of my loader is either white or blue, what might be the cause?
      A: Here are a few possible explanations to this:
    • Excessive engine oil - Reduce to the specified level
    • Low grade fuel used - Used the specified fuel
    • Fuel filter clogged – Change
    • Air cleaner clogged - Clean or change.
    • Excessive angle operation - Work on more level ground or do not stay on an angle for long lengths of time
    • Inoperative or no thermostat - Test, replace
    • Coolant in cylinders - Test, repair
    • Low cylinder compression - Test, repair
    • Worn or scored piston or rings - Repair, replace
    • Valve guides worn - Repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     


    Hydraulic & final drive

      Q: I have no drive on one side, what should I look for?
      A: Here are several things you should check:

    • Drive chain failure - Inspect the drive chain and connecting link. Replace any damaged parts.
    • Drive motor sprocket failure - Inspect the drive sprocket and splines. Replace parts as required.
    • Drive motor or hydrostatic system failure - Refer to the hydrostatic drive section. Diagnose and make repairs as required.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: I have no hydraulic power (there is no flow from the gear pump). What Should I do?
      A: Here are a few things you should check:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Adapter kit between engine and tandem pump failure - Inspect and replace the damaged parts as required. Check for proper alignment.
    • Gear pump not functioning - Inspect, test and replace damaged parts if needed.
    • Splined coupling failure in the hydrostatic pump - Inspect coupling for sheared splines. Also check pump shaft bearings.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: I have no hydraulic power, but I have full flow from gear pump. What Should I do?
      A: Here are a few things you should check:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Control linkage disconnected or binding - Inspect, adjust or replace parts.
    • Auxiliary hydraulics engaged - Disengage the switch.
    • Relief valve failure or out of adjustment - Check pressure. Adjust or repair as required.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: My final drive is noisy, what could be causing that?
      A: There are several possible causes for the noise:
    • No lubricating oil - Check oil level. Add recommended oil to correct level.
    • Axle has too much end play. (Bearing pre-load) - Check and adjust the bearing pre-load on the axle bearing.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: My hydraulic cylinders will not support a load, they "leak" down, what causes this?
      A: There could be several causes for this:
    • Control valve spools not centering - Check control linkage and control valve spool spring centering devise.
    • Cylinder seal(s) failure - Visually check for leakage, test if necessary.
    • Load check valve not functioning - Inspect, test and replace damaged parts if needed.
    • External leak between control valve and cylinders - Inspect and repair.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: My wheel studs keep shearing off, why is this happening and what can I do to prevent this from happening?
      A: You should check the wheel nuts to see if they are loose, and if so, replace the wheel studs. We recommend you check wheel nut torque daily. Torque wheel nuts to specification.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: What can cause the hydraulic oil to overheat?
      A: There are several possible reasons for this:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Oil cooler plugged or dirty - Clean the cooling fins.
    • Auxiliary hydraulics engaged - Disengage.
    • Cooling fan damaged or inoperative - Check fan for any breakage and ensure the drive belt is at the right tension.
    • Engine rpm too low - Check engine RPM and adjust if needed.
    • Temperature sender defective - Test and replace if necessary.
    • Relief valve failure or out of adjustment - Check pressure, adjust or replace.
    • Wrong type of hydraulic fluid - Replace with recommended oil.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: What causes lubrication oil leaking through the filler breather cap?
      A: There are several possible reasons for this:
    • Lubricating oil level too high - Check the oil level and drain to proper level if necessary.
    • Drive motor shaft seal leakage - Inspect and repair damaged parts.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: Why do my wheel studs keep stripping?
      A: The wheel studs keep stripping because the wheel nuts may be over tightened. In order to fix this, replace the wheel studs. Check wheel nut torque daily. Torque wheel nuts to specification.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: Why does my boom rise slowly at full rpm?
      A: There are several possible explanations for this:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Control linkages loose or worn - Inspect, adjust or replace parts.
    • Auxiliary hydraulics engaged - Disengage the switch.
    • Lifting more than rated capacity - Reduce the load.
    • Engine rpm too low - Check engine rpm and reset.
    • Relief valve failure or out of adjustment - Check pressure. Adjust or repair as required.
    • Cylinder seal(s) failure - Visually check for leakage, test if necessary.
    • Internal leakage in the control valve - Inspect and do pressure test on the control valve and repair as required
    • Limiter on control cross shaft misadjusted
    Inspect, adjust or replace worn parts.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     

      Q: Why does my hydraulic drive act erratically?
      A: There are a few possibilities for this:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Control linkages loose or worn - Inspect, adjust or replace parts.
    • Air in hydraulic system - Check for leaks between the oil reservoir and pump.
    • Load check valve not functioning - Test, inspect and replace damaged parts.
    • Control valve spool spring return mechanism not functioning - Inspect and replace damaged parts if needed.

    NOTE: Refer to repair manual for specifications, testing, removal and installation.

     


    Electrical

      Q: My boom controls seem to be stiff, what can I do to loosen it?
      A: Here are a few things you can try:
    • Cable wear – Replace
    • Pivot wear - Replace parts
    • Control valve wear - Test, repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My brake will not hold, what can cause this?
      A: Here are a few possible reasons for this:
    • Service plunger on brake valve open - Inspect and service
    • Brake disc wear or damage - Repair, replace
    • Cable could be broken or stretched - Test, repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: The aux (electric) is not functioning. What should I do?
      A: 1. First determine if there is power going to the coils on the valve. To do this, with the ignition turned to the "RUN" position (do not start), and the wires unplugged from the auxiliary coils on the valve, test with a test light to see if you have power going to them when you rock the switch on the handle. When you push the switch on one side you should have power going to one coil, and when the switch is pushed to the other side you should have power going to the other coil. If no power is going to the coil proceed to step 2.

    2. The next step would be to check the fuse in the fuse box. This is a 10 amp fuse (brown wire with yellow tracer). If the fuse is good proceed to step 3.

    3. The next thing to check would be your switch in the handle. To check this you will need to; make sure the machine is turned off, remove the seat, unplug the wires that come out of the bottom of the control lever on the LH side. Next connect the negative from an ohm meter to the green wire and test the rocker switch with by pressing one side of the switch and seeing if there is continuity one of the other wires. Do the same for the other side of the switch. If the switch is good, then there is a short in your harness. Trace out and fix short or broken wire. If the switch is faulty, replace with a new one.

    4. If you have power going back to your solenoids on your valve but the auxiliary hydraulics still won't work, check the coils for resistance to see if they are within spec. They should have 3 to 5 ohms resistance. If they do not fall within this spec then it is faulty and need replacing.

     

      Q: When I turn my key, I have no power.
      A: 1. First, make sure you have a fully charged battery. This can be done by testing it with a volt meter. You should have around 12 volts.

    2. Next, check to see if you have power at your starter. Using a test light connect the clip end of the test light on a good clean ground on the frame or engine surface and use the point end to test the stud or bolt on the engine starter where the positive cable connects.

    3. Next you will need to confirm that you have power going through the starter and solenoid. With the test light, check the starter where the ignition wire connects on. The ignition wire is usually white.

    4. If you have power coming out of the solenoid, you will have to repeat this procedure for each of the following connections until you reach the dash panel.

    5. Next you will have to test the ignition switch for power. To do this you will have to remove the dash panel to expose the back of the ignition switch. Using the test light, check to see if you have power coming into the switch through the white wire (Terminal 30). If you do, then proceed to step f.

    6. Next, turn the ignition to the run position. With the test light, check to see if you have power coming to the black with white tracer wire (terminal ACC). If you do than proceed to step g.

    7. Making sure the wires on the ignition switch do not ground out, leave the ignition turned to the run position and locate and open the fuse panel located in the engine compartment of the machine. Using the test light, test to see if there is power coming into the fuse panel buy testing the main screw. Then test both sides of each fuse for power and where each wire connects.

     


    Controls

      Q: My auxiliary is inoperative (solenoid control type), what can I do?
      A: Here are a few things you can try:
    • Blown fuse - Test, replace
    • Switch (s) failure - Test, replace
    • Aux. valve malfunction - Test, repair, replace
    • Electrical short - Test, repair, replace
    • Bad electrical ground - Test, repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My boom controls are inoperative, what can cause this to happen?
      A: Here are a few possible explanations for your problem:
    • Damaged cables, linkage – Replace
    • Safety switch(s) - Adjust, replace
    • Bad electrical ground – Repair
    • Blown fuse – Replace
    • Valve lock malfunction - Replace parts
    • Low hydraulic oil – Replenish
    • No oil pressure - Make repairs

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My boom operation is slow, what can I do to correct this?
      A: Here are a few things you can check:
    • Reservoir low on oil - Check for leaks. Fill the reservoir to the proper level with recommended oil.
    • Cable linkage binding - Replace, adjust
    • Aux. hydraulics engaged – Disengage
    • Engine RPM low – Adjust
    • Control valve relief - Check pressure, replace if necessary.
    • Cylinder seal, damage - Test, repair or replace
    • Anti-cavitation check valve spring broken - Replace.
    • Internal leak in pump due to wear - Check pump flow and repair or replace as necessary.

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My loader creeps and will not center, what causes this and how can I fix it?
      A: Here are a few things you can do:
    • Neutral detent out of adjustment - Adjust as needed.
    • Worn, loose linkage - Replace, tighten parts
    • Binding of spring bushing in spring box - Align spring box with linkage.
    • Control levers binding or rubbing with safety shields or insulation - Adjust.
    • Control lever bearings binding in lever assembly - Inspect, replace or clean as required.

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: My loader is not tracking straight, what should I look for?
      A: Here are a few things you can check:
    • Limiter stops need adjustment – Adjust
    • Binding linkage - Repair, replace
    • Hydrostatic failure - Repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: The brakes on my loader won’t release. What can I do to fix this?
      A: Here are a few things you can try:
    • Blown fuse – Replace
    • Safety switch malfunction - Adjust, replace
    • Lack of hydrostatic charge – pressure, test, repair
    • Brake valve failure - Repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation

     

      Q: What causes the steering to be "jerky" or "jumpy"?
      A: Here are a few things you can check:
    • Worn, loose linkage – Replace
    • Binding linkage - Repair, replace
    • Linkage adjustment – Adjust
    • Low charge pressure - Repair, replace

    NOTE: Refer to repair manual for specifications, testing, removal and installation