section 7 - timberpro inc · reflective vests and eye, ear and respiratory protection as required...

Troubleshooting Guide - Introduction7.0.1Form M053

Section 7.0

Troubleshooting Guide -Introduction

Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0.2

Simplified Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0.3

The 7 Step Troubleshooting Method . . . . . . . . . . . . . . . . . . . . . . . . . 7.0.3

Other Helpful Troubleshooting Hints . . . . . . . . . . . . . . . . . . . . . . . . . 7.0.5

Troubleshooting Guide - Introduction 7.0.2

Troubleshooting Safety

You must read and understand the warningsand basic safety rules, found in Group 1 of thismanual, before performing any troubleshootingprocedures.

For additional troubleshooting guidelines, seethe manufacturer’s manuals provided with themachine for the engine and any fellingattachment when installed.

Form M053

At operating temperature, the engine, exhaustsystem components, cooling systemcomponents and hydraulic system componentsare HOT. Any contact can cause severe burns.

00017

Diesel exhaust fumes contain elements that arehazardous to your health. Always run engine in awell ventilated area. If in an enclosed space,vent exhaust to the outside.

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Before performing maintenance or repairs on themachine, consult this manual and follow therecommended procedures.

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Use recommended protective clothing and safetydevices such as gloves, safety boots, safety hat,reflective vests and eye, ear and respiratoryprotection as required by job conditions.

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Comply with the instructions in this manual andyour company’s regulations for the operation ofthis machine.

YOU MUST BE FULLY TRAINED to operate thismachine and its felling attachment.

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NOTICE

Troubleshooting Guide - Introduction7.0.3

Simplified TroubleshootingThere are two ways to tackle and find the cause ofproblems. The first is by guessing and replacingparts until the problem is corrected (expensive andtime consuming). The second is by troubleshooting(cheap and consistent). With the increasing cost ofparts and machine downtime, replacing parts untilthe problem is corrected is prohibitive andextremely inefficient. This has madetroubleshooting a very valuable skill.

Troubleshooting is done by stepping back,examining the facts and symptoms, isolating thecause of the problem, and then verifying the causeof the problem by testing. Parts are only orderedafter confirming the problem. This reduces costs byonly replacing parts that require replacing andreducing downtime by getting machines up andrunning quickly. Troubleshooting may sound slowand complicated, but it isn’t. Once a person haslearned the basic steps of troubleshooting and hasused them a few times, it is a quick and easy way tosolve problems.

With this in mind you decide which way you want tosolve problems you encounter. If you want to do itby being a parts replacer... read no further andaccept the higher costs of repair problems. If youwant to troubleshoot and repair problemseconomically... read on.

The 7 Step TroubleshootingMethodThere are several methods of troubleshooting thatcan be used to solve problems. The method we aregoing to explain is the called the Seven StepMethod. This method is simple to learn and easy touse. As with all methodical troubleshootingmethods, if used correctly, it will produce accurateand consistent results. The seven steps oftroubleshooting are;

1) Know the System2) Ask the Operator3) Operate the Machine4) Inspect the Machine5) List the Possible Causes6) Reach a Conclusion7) Test Your Conclusion

Form M053

Pressure can be maintained in system circuitslong after the engine and pumps have been shutdown. Release trapped pressure in hydraulic,fuel, and cooling system lines before performingany maintenance or repair procedures.

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Keep your head, hands, and feet clear of allmoving parts.

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Keep yourself, all objects and tools away frommoving fan blades. Fan blades will cut or throwany object dropped or pushed into them.

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Troubleshooting Guide - Introduction 7.0.4 Form M053

The only time parts should be replaced is after theseventh step. Let us now examine the seven stepsand how each is used.

1) Know The System

To be able to troubleshoot, one must be familiar withand understand the systems on the machine bydoing their homework. What we mean is getting toknow about the machine through the productmanuals, bulletins, technical schools and coursesavailable on the machine, and from otherknowledgeable personal. This may seemoverwhelming, but it is not. Much of it can belearned over a period of time and the rest isgenerally available if needed immediately. With thisknowledge a person is prepared to tackle step #2.

2) Ask The Operator

This is an important step that many people skip.Operators are a valuable part of troubleshooting.Only they can tell you how the machine acted whenthe problem first started to occur and if any otherusual things happened also. They can also tell youif any adjustments were tried, plumbing movedaround, or various other little bits of valuableinformation. Once you have thoroughly interviewedthe operator, you are ready to move on to step #3.

3) Operate The Machine

It is important that you operate the machine yourselfand experience the problem. You know what aproper machine feels and operates like. Find outwhat feels different now. This will also allow you toverify the operator’s story about the machine and itsproblem.

When you operate the machine you should see if itfeels different. Is it sluggish, do the controls feelstiff, unresponsive, overly aggressive, spongy, etc.

How do the gauges read, are they normal? How isthe performance? Is it slow, erratic, or does notrespond at all?

Are there any unusual smells or do you seeanything abnormal like smoke?

Are there any strange or unusual noises? If so,where does it seem to come from? What doe itsound like? What functions cause the noises?

You should experience and investigate the problem

with all the senses you possesses (Look, Listen,Feel, Smell, and Taste).

Your senses are very sensitive, can accumulate andanalyze a huge amount of information, and are aintegral part of troubleshooting. Don’t ignore them,use them, then move on to step #4.

4) Inspect The Machine

Now that you know what the machine is acting like,it is time to visually inspect the machine using allfive senses again (Look, Listen, Feel, Smell, andTaste).

Are there any oil leaks? How is the oil in thereservoir, is it milky, foaming, low level, too thin, toothick, dirty, etc.?

How are the filters, are they plugged?

Feel the reservoir and other components. Are theyoverly hot? Is the oil cooler plugged with debris?Any collapsed lines?

These are just examples. When you inspect themachine, specifically the affected system, it will giveyou many excellent clues to the root of the problem.Now move on to step #5.

5) List The Possible Causes

You are now ready to list the possible causes of theproblem based on what the operator has told youand the information you have gained from operatingand inspecting the machine. All your informationwill provide clues that will point to a problem or aseries of problems. Analyze these clues andcombine them with your knowledge of the machine.Write down each possible cause of the problem,even if it seems very remote or unlikely. Aftermaking your list move on to step #6.

6) Reach Your Conclusion

Look over your list of possible causes and markdown which is the most likely and easiest to confirm.The troubleshooting guides in this section can helpyou with this. Reach a conclusion on the mostreasonable causes of the problem and plan tocheck or confirm these possibilities first. Now moveon to step #7.

Troubleshooting Guide - Introduction7.0.5

7) Test Your Conclusions

This is another step that many people skip and goto replacing parts, hoping that it corrects theproblem. You need to test your conclusions to verifywhat has actually caused the problem. Only aftertesting your conclusions should parts be orderedand replaced.

Many of the conclusions can be verified withoutfurther testing by logically analyzing the informationyou already have.

Were all functions bad? If so, then the componentsthat are only common to all parts of the systemcould cause the problem. These may includepumps, filters, coolers, tank, etc.

Was only one circuit or function bad? If so, then youcan eliminate any component that is common to allfunctions. Doing this will narrow your list ofconclusions down to just a few items.

The remaining conclusions can now be tested byusing the test & adjustment procedures found in thismanual to confirm which item or component causedthe problem. Once testing has been completed,you will know the caused the problem and be ableto only replace the part(s) required. This simplifiesthe repair and reduces the total cost by eliminatingadditional unneeded parts.

Congratulations on entering the world oftroubleshooting!

Other HelpfulTroubleshooting HintsWhen troubleshooting problems arise, always try toisolate the problem by starting with a simpleprocedure first.

Depending on the problem, it will usually involve apressure check for either system pilot pressure orvarious pump pressures such as charge pressure,standby pressure, or POR pressure. There arequick-couple gauge port adapters provided for eachof these pressure checks.

In case of an implement or travel problem, it is agood idea to check the return filters first. Bronze orbrass flakes in the filters would indicate a pumpfailure. DO NOT allow unfiltered oil to flow into themain tank. See “Changing Return Filters” inSection 5.6.

Cross pilot lines or electrical harness leads to see ifthe problem is in the control circuit. If the problemmoves with the pilot lines or electrical harnessleads, the problem is likely in the control circuit.

Cross hoses at the A & B work ports of the problemfunction valve section to see if the problem appearsin the opposite direction. If the problem continues,the problem is likely in the valve section.

Change problem function hoses to a different valvesection. If the problem continues, the problem islikely in the cylinder or motor.

Form M053

Troubleshooting Guide - Introduction Form M053

THIS PAGE LEFT BLANK FOR NOTES

Troubleshooting Guide - General Machine Performance7.1.1Form M297

Section 7.1

Troubleshooting Guide -General Machine Performance


Troubleshooting Guide - General Hydraulic Problems:No Functions Will Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.4All Functions Slow Or Sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.6Excessive Noise From Pump Area . . . . . . . . . . . . . . . . . . . . . . . . 7.1.7Hydraulic Tank Turbo Boost Not Building Pressure . . . . . . . . . . . . 7.1.9Hydraulic Oil Coming From Tank Overflow Hose . . . . . . . . . . . . . 7.1.10Low Hydraulic Oil Warning Sounds, But Oil Level OK . . . . . . . . . . 7.1.11Low Hydraulic Oil Warning Does Not Work . . . . . . . . . . . . . . . . . . 7.1.12

Troubleshooting Guide - Machine Overheat Problems:Engine & Hydraulics Overheating . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.15Only Engine Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.16Wheel Drive Hydraulics Overheat . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.17Implement Hydraulics Overheating . . . . . . . . . . . . . . . . . . . . . . . . 7.1.19All Hydraulics Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.20

Troubleshooting Guide - General Machine Performance 7.1.2



For additional troubleshooting guidelines, seeSection 7.1 and the manufacturer’s manualsprovided with the machine for the engine andfelling attachment when installed.

Form M297


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Troubleshooting Guide - General Hydraulic Problems

PROBLEM PROBABLE CAUSE ACTION

1) Engine Runs, a) No Power To Controls.No Functions See Figure 1.Work

- Check the face of the control boxesfor green power lights. If there are nopower lights, continue with “1b”.If there are power lights, go to “1d”.

b) No Power To Control Boxes:Tripped control circuit breaker.See Figure 2.

- Reset 8 amp breaker in dash panel.

c) No Power To Control Boxes:Safety interrupt door switchmalfunction. See Figure 3.

- Replace safety interrupt door switch.

Form M297Troubleshooting Guide - General Machine Performance 7.1.4

Figure 3: Safety Interrupt Switch

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Figure 2: Control Circuit Breaker - Typical

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Figure 1: Control Box Green LEDs

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1) Engine Runs, d) No Pump Pressure Output:No Functions Damaged flexplate in pump driveWork. (Cont’d) transmission. See Figure 4.

NOTE: Broken pump drivetransmission flexplate failures arerare. Be sure all other possiblecauses have been explored beforeremoving these components.

- If there is no evidence of a pumpfailure, the pump drive transmissionflexplate may be damaged whichwould prevent any pump operation.See Figure 4. Remove and inspectthe pump drive transmission flexplate.Replace the flexplate if damaged.

Form M297 Troubleshooting Guide - General Machine Performance7.1.5

Figure 4: Flexplate

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2) All Functions a) Hydraulic Oil Viscosity Too Low - Follow recommended machineSlow Or For Ambient Conditions. warm-up procedures in Section 4.3.Sluggish. Change oil to an ISO grade that

matches your ambient conditions ifrequired.

b) Poor Engine Performance. - See “Engine Troubleshooting Guide”,Section 7.4.

c) Low Voltage To Control Boxes.See Figure 5.

- Check input voltage to control boxes.See “Loader Implement ControlSystem” test, Section 8.6.

Figure 5: Control Boxes

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3) Excessive a) Hydraulic Tank Not Pressurized. - See Problem #4, “Hydraulic TankNoise From Turbo Boost Not Building Pressure”,Pump Area. in this Section.

b) Air In Pump Suction LIne(s).Pump suction line shut-off valvepartially closed causing pumpcavitation. See Figure 6.

- Ensure all pump suction line shut-offvalves are fully open and retained bytie straps.

c) Air In Pump Suction Line(s). - Tighten all suction line connections.Loose connections in pumpsuction lines.

d) Air In Pump Suction LIne(s). - Check all pump suction lines. Collapsed pump suction line. Replace any collapsed lines.

e) Air In Pump Suction LIne(s).Low hydraulic oil level in tank.See Figure 7.

- Low oil level can allow the suctionstrainers to be exposed to air whentraveling up a slope. Check oil levelat sight gauge. Oil should be in the“green” zone at operating temperature.Add oil if required. See Section 5.2.

Figure 6: Pump Suction Line Shut-off Valve

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Figure 7: Hydraulic Oil Level Sight Gauge

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3) Excessive f) Air In A Pump Suction Line.Noise From Air entering hydraulic tank fromPump Area. cylinders and motors.(Cont’d) See Figure 8.

- Trapped Air can enter the hydraulictank during initial start up or afterreplacing a major hydrauliccomponent. Remove the hydraulictank access cover and check fortrapped air bubbles in the oil with aflashlight. If there are air bubbles, orthe oil has a foamy appearance,de-aerate the machine.See Section 5.9.

g) Failing Hydraulic Pump. - Check all pump case drains forshavings or flakes. Also check thecase drain return filter for metalshavings and flakes. If found,replace pump.

- If no metal shavings or flakes arefound, perform case drain flow test forthe component. If case drain flow isexcessive, the component may benear failure. Replace component ifrequired. See Section 8.2 and 8.3.

h) Plugged Pump Suction Line - Check all pump suction line strainersStrainer. for debris. Remove and clean plugged

strainer.

NOTE: The hydraulic tank will needto be drained to remove and clean astrainer. See “Clean Hydraulic Tank& Change Hydraulic Oil”, Section 5.8.

i) Rear engine mounts worn. - Check and inspect for worn ordamaged rubber isolators on the rearengine mounts. Replace isolators ifrequired.

Figure 8: Hydraulic Tank Access Cover

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4) Hydraulic Tank a) Turbo Boost Release ValveTurbo Boost Open. See Figure 9.Not BuildingPressure.

- Close the turbo boost release valvelocated in the upper left corner of thehydraulic tank near the air cleaner.

b) Hydraulic Tank Safety Relief CapLoose Or Seal Is Worn.See Figure 10.

- Tighten relief cap. If turbo boost willstill not build pressure, replace therelief cap, Timbco PN# 18135.Damage to hydraulic componentsmay result if incorrect relief cap isused.

c) Turbo Boost Regulator.Malfunction. See Figure 11.

- Perform “Hydraulic Tank Turbo BoostRegulator” test, Section 8.1.

Figure 9: Turbo Boost Release Valve

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Figure 11: Turbo Boost Regulator - Typical

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Figure 10: Hydraulic Tank Safety Relief Cap

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5) Hydraulic Oil a) Machine Not Level During - If the machine is operated on a steepComing From Operation. slope and facing downhill, the oil levelTank Overflow can reach the bottom of the reliefHose. stem inside the tank. If the pressure

in the tank exceeds the relief capsetting while the stem is submergedin oil, the oil will be purged instead ofair. Since the machine does not havea leveling capability, little can be doneto prevent this from occurring otherthan avoiding operation on a steepslope facing downhill.

b) Hydraulic Oil Tank Overfilled.See Figure 12.

- Check oil level at sight gauge. Oilshould be in the “green” zone atoperating temperature. Drain someoil if required. See Section 5.2.

c) Hydraulic Tank Safety ReliefCap With Too Low A Setting. See Figure 13.

- Replace relief cap with correct reliefcap, Timbco PN# 18135. Damage tohydraulic components may result ifincorrect relief cap is used.

Figure 12: Hydraulic Oil Level Sight Gauge

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Figure 13: Hydraulic Tank Relief Cap

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5) Hydraulic Oil d) Turbo Boost Pressure TooComing From High. See Figure 14.Tank OverflowHose. (Cont’d)

- Perform “Hydraulic Tank Turbo BoostRegulator” test, Section 8.1.

6) Low Hydraulic a) Hydraulic Oil Level SensorOil Warning Malfunction. See Figure 15.Sounds, ButOil Level OK.

- Remove and replace the hydraulic oillevel sensor.

b) Electrical Ground Or Short - Inspect for a worn or damaged wireBetween Sensor And Indicator harness. Repair or replace wires orIn Dash. harness if required.

Figure 14: Turbo Boost Regulator (Typical)

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Figure 15: Hydraulic Oil Level Sensor

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Troubleshooting Guide - General Machine Performance 7.1.12 Form M297


7) Low Hydraulic a) No Power To Low Hydraulic OilOil Warning Level Warning Indicator.Does Not Work. See Figure 16.

- Check for power at the low hydraulicoil level warning indicator. Repairwiring if required.

b) Burnt Out Indicator Bulb. - Replace Bulb.See Figure 16.

c) Open Circuit Between Sensor - Inspect for a loose connection orAnd Indicator In Dash. broken wire. Tighten connections or

replace wires if required.

d) Hydraulic Oil Level SensorMalfunction. See Figure 17.

- Remove and replace the hydraulic oillevel sensor.

Figure 16: Low Hydraulic Oil Level Warning Indicator (Typical)

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Figure 17: Hydraulic Oil Level Sensor

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Troubleshooting Guide - Machine Overheat Problems


6) Engine a) Blocked Airflow Across& Hydraulics Radiator/Oil Cooler Fins:Overheating. Forest debris plugging debris

screen and radiator/oil cooler fins.See Figure 18.

- Keep radiator/oil cooler fins clean.

b) Blocked Airflow Across - Check and repair or replace damagedRadiator/Oil Cooler Fins: components.Damaged radiator/oil cooler fins,debris screen or louveredradiator guard preventing propercooling air flow. See Figure 1.

c) Re-circulation Of Hot EngineAir Across Radiator/Oil Cooler.See Figure 19.

- Be sure rubber baffle is in placearound the entire radiator/oil coolerassembly to prevent hot air bypass.

NOTICE Overheating of both the engine and hydraulics will most likely be the result of notenough cooling air flowing past the radiator and oil cooler.

Figure 18: Radiator/Oil Cooler Fins& Debris Screen

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Figure 19: Radiator/Oil Cooler Baffle

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6) Engine d) Not Enough Cooling Air Flow& Hydraulics Across The Radiator/Oil CoolerOverheating. Fins. Damaged engine fan or(Cont’d) missing/damaged fan shroud.

See Figure 20.

- Check engine fan and fan shroud.Replace damaged or missingcomponents.

d) Not Enough Cooling Air Flow - Ensure fan belt is correct for engineAcross The Radiator/Oil Cooler installed. Inspect fan belt and pulleysFins. Incorrect fan belt or fan belt for wear and correct tension. Seeworn or slipping. Section 5.4.

e) Not Enough Cooling Air Flow - Ensure proper engine fan is installedAcross The Radiator/Oil Cooler for the application. Engine fans areFins. Incorrect engine fan available in sucker and blower typesinstalled. (sucker fan installed at factory).

See your OEM Replacement PartsManual for part numbers and orderinginformation.

f) Not Enough Cooling Air FlowAcross The Radiator/Oil CoolerFins. Incorrect engine fanspacer installed. See Figure 21.

- Ensure proper engine fan spacer isinstalled for the fan type being used.See your OEM Replacement PartsManual for part numbers and orderinginformation.

Figure 20: Engine Fan & Shroud

00111

Figure 21: Engine Fan Spacer

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6) Engine g) Not Enough Cooling Air Flow - Ensure engine fan is installed& Hydraulics Across The Radiator/Oil Cooler correctly. Normally, any informationOverheating. Fins. Engine fan installed tamped on the fan hub will face the(Cont’d) backwards. the radiator/oil cooler when installed

correctly.

h) Not Enough Cooling Air Flow - Check and adjust engine rpm. SeeAcross The Radiator/Oil Cooler Section 8.5.Fins. Incorrect engine rpm.



7) Only Engine a) Thermostat Stuck Closed. - Check and correct or replace.Overheating. See engine manuals supplied with

with the machine for procdure.

b) Incorrect thermostat Installed - Replace thermostat with one that hasFor Ambient Conditions. a lower opening temperature. See

engine manuals supplied the machinefor procdure.

c) Excessive Coolant Anti-Freeze - Check coolant for correct anti-freezeRatio Causing Gelling. ratio and adjust as required. See

Section 5.6.

d) Failed Water Pump. - Check water pump and replace ifrequired. See engine manualssupplied the machine for procdure.

e) Engine Water TemperatureGauge Malfunctioning.See Figure 22.

- Check engine water temperature witha master gauge known to be good.Replace gauge if required.

f) Failed Head Gasket Allowing. - Open the radiator cap and inspect Combustion Gases Into The engine coolant for gas bubbles while Engine Coolant. the machine is running. If combustion

gas bubbles are present, contact yourTimbco dealer for further instructions.

g) Engine Is Overfuelled. - Contact your Timbco dealer for furtherinstructions.

Figure 22: Engine Water Temperature Gauge

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8) Wheel Drive a) Wheel Drive Pump PCO ReliefHydraulics Out Of Adjustment.Overheat. See Figure 23.

- Perform “Wheel Drive Pump PCOPressure” test. Adjust or replace thePCO relief. See Section 8.3.

b) Wheel Drive Pump DirectionalRelief Out Of Adjustment.See Figure 24.

- Perform “Wheel Drive PumpDirectional Relief Pressure test.Adjust or replace the reliefs ifrequired. See Section 8.3.

c) Running Wheel Drives Hard And - Running the wheel drive functionsExcessively Lugging Engine hard or rough forces oil over reliefsDown. causing heat. Use correct operating

technique.

Figure 24: Wheel Drive PumpHigh Pressure Reliefs

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Figure 23: Wheel Drive Pump PCO

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8) Wheel Drive d) Wheel Drive Motor Case DrainHydraulics Orifice(s) Plugged.Overheat. See Figure 25.(Cont’d)

- Remove each wheel drive motor casedrain (flush) orifice plug in the motorhead bottom end cap. Clear anydebris plugging the orifice spool end.

e) Leakage In Rotary Manifold - Contact your dealer.Between Wheel Drive Galleries.

Figure 25: Wheel Drive Motor Case Orifice

00412



9) Implement a) Loader Or Arch Grapple Valve Hydraulics Port Relief Out Of Adjustment.Overheating. See Figure 26.

- Perform “Implement Valve PortRelief” test. Adjust or replace therelief. See Section 8.2.

b) Clam Bunk Valve Port ReliefIncorrect or Malfunctioning.See Figure 27.

- Perform Clam Bunk Valve Port Relief”test. Replace the relief if required.See Section 8.8.

c) Implement Pump POR Set Too - Perform “Implement Pump PORLow. Pressure” test, Section 8.2.

d) Internal Leakage In Implement - Contact your dealer. Valve.

e) Internal Leakage In Clam Bunk - Contact your dealer Valve.

f) Excessive Volume Of Oil Flow - Ensure hoses and/or tubelines are Down Too Small Of Lines To the correct size for the oil flowGrapple or Cutting Attachment. required.

Figure 27: Clam Bunk ValveSection Port Reliefs

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Figure 26: Implement Valve Port Relief (Typical)

00413



10) All Hydraulics a) Excessive Pump Or Motor Case - Perform wheel drive pump, wheelOverheating. Leakage That Is Not Routed To drive motor, loader implement pump,

The Oil Cooler Before Going To and swing motor case drain leakageTank. tests. See Sections 8.2 and 8.3.

b) Oil Cooler Thermal BypassValve Malfunction.See Figure 28.

- Perform “Oil Cooler ThermalBypass Valve” test, Section 8.1Replace oil cooler thermal bypassvalve if required.

c) Oil Cooler Plugged Internally. - Perform “Oil Cooler Performance” test,Section 8.1.

d) Wrong Hydraulic Oil Viscosity. - Change hydraulic oil viscosity tomatch ambient conditions. See“Appendix A” or hydraulic oil viscositydecal inside the swing-out pumpaccess guard.

Figure 28: Oil Cooler Thermal Bypass Valve

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Troubleshooting Guide - Implement Functions7.2.1Form M298

Section 7.2

Troubleshooting Guide -Implement Functions


Troubleshooting Guide - Implement Function Problems:No Implement Functions Work, Wheel Drives OK . . . . . . . . . . . . . 7.2.4Only Functions On Single Hand Control Do Not Work . . . . . . . . . 7.2.7All Implement Functions Slow Or Sluggish . . . . . . . . . . . . . . . . . . 7.2.8Single Function Slow Or Sluggish In Both Directions . . . . . . . . . . 7.2.10Single Function Slow Or Sluggish In One Direction . . . . . . . . . . . 7.2.13All Functions Feel Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.16Single Function Feels Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.17Load Drift, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.19Load Drift, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.20

Troubleshooting Guide - Implement Functions 7.2.2 Form M298





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Troubleshooting Guide - Implement Function Problems


1) No Implement a) Pump Destroke Activated:Functions Pump destroke circuit remains Work, Wheel activated after starting engine.Drive OK.

NOTE: This condition generallyexists immediately after using thepump destroke during enginestart.

- Disconnect the harness (green wire)from the load sense signal dump valvecoil in port “SV2” of the upper solenoidmanifold. See Figure 1.

If the implement functions work withthe wire lead removed, the pumpdestroke switch is sticking or failed.Free the switch or replace if required.See Figure 2.

If the implement functions still do notwork, remove the load sense dumpvalve cartridge and check for debrisor damaged seals that are allowingsignal oil to bypass. Replace seals orvalve cartridge if required.

Form M298Troubleshooting Guide - Implement Functions 7.2.4

Figure 2: Pump De-Stroke Switch

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Figure 1: Load Sense Signal Dump Valve

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1) No Implement b) No Voltage To Control Boxes.FunctionsWork, Wheel NOTE: Wheel drive functionsDrive OK will also not work if the control(Cont’d) boxes have no voltage.

- Check input voltage to control boxes.See “Implement Control System” test,Section 8.6.

c) Load Sense Orifice Or ShuttleBlocked. See Figure 4.

- Locate the load sense shuttle on theunderside of the implement pump.Remove the shuttle and the orificefitting between the shuttle and pumpcompensator. Check for debrisblocking the orifice or causing theshuttle to stick.

d) No Implement Pump Output - Perform “Implement Pump Stand-byPressure” test, Section 8.2.

If no standby pressure, the problem isat the implement pump, go to 1e.

If standby pressure is ok, but noimplement functions will work, theproblem is the load sense signalbypassing internally in the maincontrol valve and not reaching thepump. Contact your dealer.

Form M298 Troubleshooting Guide - Implement Functions7.2.5


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Figure 4: Load Sense Orifice Fitting& Shuttle

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1) No Implement e) No implement Pump Output:Functions Worn pump or internal failure.Work, Wheel See Figure 5.Drives O.K.(Cont’d) NOTE: If an internal pump/motor

failure is suspected, always checkthe component’s case drain lineand the case drain return filter formetal particle contamination first.

- Check the case drain filter for metalflakes and perform “Implement PumpCase Drain Flow” test, Section 8.2.

If metal flakes are found in the casedrain filter or case drain flow isexcessive, the implement pump isworn or failed. Replace the implementpump.

Figure 5: Implement Pump

00518



2) Only Functions a) Control Box Malfunction. On Single Hand See Figure 6.Control Do NotWork.

- Check the face of the control boxesfor a red error light. The red errorlight means there could be twoproblems:

- Low voltage to the control boxfrom the power source. See“Implement Control System” test,Section 8.6.

- Function input or control boxamplifier card malfunction.Contact your dealer.

Figure 5: Control Box Red LEDs(LH Box = LH Control, RH Box = RH Control)

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3) All Implement a) Low Voltage To Control Boxes.Functions See Figure 7.Slow OrSluggish. NOTE: Wheel drive functions

will also be slow and sluggish ifhe control boxes have lowvoltage.

- Check input voltage to control boxes.See “Implement Control System”test, Section 8.6.

b) Load Sense Orifice Blocked. See Figure 8.

- Locate the load sense orifice fittingbetween the shuttle and implementpump compensator. Check for debrisblocking the orifice.

c) Incorrect Implement Pump - Perform”Implement Pump Stand-By”Standby and/or POR and ”Implement Pump POR Pressure”Pressures. tests, Section 8.2.

If pump pressures are ok, but loaderimplement functions are sill slow andsluggish, the problem is the loadsense signal not reaching theimplement pump, go to “3d”.

If correct pump pressures cannot bereached, the problem is in theimplement pump, go to “3e”.

Figure 7: Control Box Red LEDs

00243

Figure 8: Load Sense Orifice Fitting

00504



3) All Implement d) Load Sense Signal NotFunctions Reaching Pump: Load senseSlow Or shuttle valve leaking signal.Sluggish. See Figure 9.(Cont’d)

- Remove all lines from the load senseshuttle valve except the #6 line goingto the control valve. Cap all fittings.

If implement functions work properlywith lines disconnected, replace theshuttle valve.

NOTE: If there is more than oneshuttle valve, reconnect each lineseparately until the leak is found.

If implement functions are still slowor sluggish, the problem is the loadsense signal bypassing internally inthe main control valve. Contact yourdealer.

e) Implement Pump Malfunction:Compensator spools sticking orcontrol spring broken. SeeFigure 10.

- Remove and clean spools. Be surethe spools move freely. Check for abroken control spring and replace ifrequired.

Figure 10: Implement Pump Compensator(Typical)

00375

Figure 9: Load Sense Shuttle Valve

00504


4) Single a) Internal leakage In Cylinder Or - Perform cylinder or motor leakageFunction Slow Motor. tests, Section 8.2.Or SluggishIn Both NOTE: If the swing function isDirections. slow or sluggish in both directions,

first check to be sure that theswing detent feature is notactivated. It is possible tooperate the swing function withthe swing detent activated butoil flow is very restricted..

b) Function Control Input Card Not Responding To ControlInput Signals. See Figure 11.

- Operate the affected function andwatch its control box. As the controlis moved, green lights should appear,one light for each direction the controlmoves to operate that function.

- If green lights appear for bothdirections the control is moved,go to “4c”.

- If green lights do not appear forboth directions the control ismoved, the control input card forthat function has failed. Contactyour dealer.


Figure 11: Control Boxes(LH Box = LH Control, RH Box = RH Control)

00243


4) Single c) Function Control Input Card - If the function is operated and greenFunction Slow Out Of Adjustment. lights appear on the control box forOr Sluggish both directions the control is moved,In Both the function input card may just beDirections. adjusted too slow. Adjust the(Cont’d) function’s MIN, MAX and RAMP to

suit. See “Implement Control System”test, Section 8.6.

If the function input card cannot beadjusted, go to “4d”.

d) Function Control Input Card - If the function is operated and greenMalfunction. lights appear on the control box but

the function input card cannot beadjusted, test the return voltage signalfrom the control. See “ImplementControl System” test, Section 8.6.

- If the return voltage from thecontrol is less than 4.7 volts in bothdirections, the function input cardhas failed. Contact your dealer.

- If the return voltage from thecontrol is at least 4.7 volts in bothdirections, the problem is in themain control. valve, go to “4e”.

e) Compensator Dampening Orifice In Function ControlValve Section Plugged. See Figure 12.

- Remove the compensator dampeningorifice from the function’s controlvalve section. Clean debris from theorifice and re-install.


Figure 12: Compensator Dampening Orifice

00466



4) Single f) Function Valve SectionFunction Slow Compensator SpoolOr Sluggish Malfunction. See Figure 13.In BothDirections.(Cont’d)

- Remove the compensator spool fromthe function’s control valve section.

- Be sure spool does not stick orbind. Clean and inspect for nicksor scoring. Replace spool ifrequired.

- Check for a broken compensatorspool control spring. Replacecontrol spring if broken. Be sureto remove all pieces of brokenspring.

g) Proportional Solenoid OrificePlugged Or Wrong Size.See Figure 14.

- Remove the proportional solenoidorifices from the function’s controlvalve section. Clean and check forcorrect orifice size. See “Appendix A”.Re-install orifices.

Figure 13: Compensator Spool

00466

Figure 14: Proportional Solenoid Orifice

00466



5) Single a) Function Control Input Card - Adjust the function’s MIN, MAX andFunction Slow Out Of Adjustment. RAMP to suit. See “ImplementOr Sluggish Control System” test, Section 8.6.In OneDirection.

b) Proportional SolenoidMalfunction. See Figure 15.

- Swap the harness leads between theproportional solenoids of the problemfunction’s control valve section.

- If the problem does not changedirection with the harness swap,a proportional solenoid may havefailed. Replace the solenoid with aknown good solenoid, or performthe “Implement Valve ProportionalSolenoid Continuity” test,Section 8.6.

- If the problem does not changedirection with the harness swap,and proportional solenoids testok, the problem is in the maincontrol valve, go to “5d”.

- If the problem changes directionswith the harness swap, the problemis in the control system, go to “5c”.

Figure 15: Proportional Solenoid

00466



5) Single c) Control System Malfunction:Function Slow Control box not sending properOr Sluggish signal to control valve solenoids.In One See Figure 16.Direction.(Cont’d)

- Operate the affected function to findwhat channel it operates on from thecontrol box (indicated by green light).Perform a control output voltage teston the affected channel. See“Implement Control System” test,Section 8.6.

- If output voltage is ok, the problemis likely a failed amplifier card in thecontrol box. Contact your dealer.

- If output voltage is not ok, theproblem is a failed potentiometerin the hand or foot control.Replace the failed potentiometer. See appropriate procedure inSection 9.6.

d) Function Port Relief Out OfAdjustment. See Figure 17.

- Perform “Implement Valve Port Relief”test, Section 8.2. Adjust or replacethe relief, if required.


00243

Figure 9: Loader Implement ValveFunction Port Relief

00466



5) Single e) Proportional Solenoid OrificeFunction Slow Plugged Or Wrong Size.Or Sluggish See Figure 18.In OneDirection.(Cont’d)


f) Internal leakage In Cylinder Or - Perform cylinder or motor leakageMotor. tests, Section 8.2.

g) Plugged Load Sense Orifice - Contact your dealer.In Function Valve Section MainSpool.


00466


6) All Functions a) Hydraulic Tank Not Pressurized. - See Problem #4, “Hydraulic TankFeel Jerky. Turbo Boost Not Building Pressure”,

Section 7.1.

b) Incorrect Implement Pump - Perform “Implement Pump Stand-byStand-by Pressure. Pressure” test, Section 8.2.

If standby pressure is ok, but functionsare sill jerky, go to “6c”.

If correct pump pressures cannot bereached, the problem is likely in theimplement pump compensator,go to “6d”.

c) Control Valve Return Oil 150 PSICheck Valve Stuck Open. See Figure 19.

- Remove 150 PSI and inspect fordamage or debris. Clean or replacecheck valve.

d) Implement Pump Malfunction:Compensator spools sticking orcontrol spring broken. SeeFigure 20.

- Remove and clean spools. Be surethe spools move freely. Check for abroken control spring and replace ifrequired.


Figure 19: 150 PSI Return Check Valve(Shown during assembly for clarity)

00505

Figure 20: Implement Pump Compensator(Typical)

00375



7) Single a) Function Control Input Card - Adjust the function’s MIN, MAX andFunction Feels Out Of Adjustment. RAMP to suit. See “Loader ImplementJerky. Control System” test, Section 8.6.

c) Erratic Control Output SignalBeing Received From Control.See Figure 21.

- Operate the affected function to findwhat channel it operates on from thecontrol box (indicated by green light).Perform a control output voltage teston the affected channel. See“Implement Control System” test,Section 8.6.

If output voltage signal is not aconsistently smooth increase as thecontrol is moved to full “ON”, thelinear potentiometer may be fused.Replace the failed potentiometer. See appropriate procedure inSection 9.6.


00243



7) Single c) Proportional Solenoid OrificeFunction Feels Plugged Or Wrong Size.Jerky. (Cont’d) See Figure 22.


d) Function Valve SectionCompensator Spool StickingFull Open. See Figure 23.

- Remove the compensator spool fromthe function’s control valve section.Be sure spool does not stick or bind.Clean and inspect for nicks or scoring.Replace spool if required.

Figure 23: Compensator Spool

00466


00466



8) Load Drift, a) Function Port ReliefCylinder. Malfunction. See Figure 24.


b) Internal leakage In Cylinder. - Perform “Cylinder Leakage” test,Section 8.2.

NOTE: If working with the grapplecylinder, also check for leakage inthe rotator seals.

c) Function Valve SectionMain Spool Centering Spring.See Figure 25.

- Remove the valve section main spoolcentering spring. Inspect thecentering spring and main spool fordamage. Replace if required.

Figure 25: Valve Section Main Spool& Centering Spring

00466


00466



9) Load Drift, a) Internal leakage In Cylinder. - Perform “Cylinder Leakage” test,Motor. Section 8.2.

b) Function Port ReliefMalfunction. See Figure 26.


c) Anti-Cav Valve Cross OverRelief Leakage (Swing FunctionOnly) See Figure 27.

- Remove the anti-cav cross over reliefsand inspect for damaged seals.Replace seals or cartridge, if required.

Figure 27: Anti-Cav Cross Over Relief Valve(Typical)

00414


00466



9) Load Drift, d) Function Valve SectionMotor. (Cont’d) Main Spool Centering Spring.

See Figure 28.

- Remove the anti-cav cross over reliefsand inspect for damaged seals.Replace seals or cartridge, if required.

Figure 28: Valve Section Main Spool& Centering Spring

00466

Troubleshooting Guide - Wheel Drive Functions7.3.1Form M299

Section 7.3

Troubleshooting Guide -Wheel Drive Functions


Troubleshooting Guide - Wheel Drive Problems:Wheel Drive Will Not Work, Implement Functions OK . . . . . . . . . . 7.3.4Wheel Drive Will Not Work And No Charge Pressure . . . . . . . . . . 7.3.6Wheel Drive Slow Or Sluggish In Both Directions . . . . . . . . . . . . . 7.3.7Wheel Drive Slow Or Sluggish In One Direction . . . . . . . . . . . . . . 7.3.9Failure Of High Pressure Driveline Hose . . . . . . . . . . . . . . . . . . . . 7.3.10Machine Creeps In Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.11Wheel Drive Maximum Displacement Lock Will Not Engage

(Standard dual wheel drive motors) . . . . . . . . . . . . . . . . . . . . . . 7.3.122-Speed Motor Shift Will Not Work

(Optional single wheel drive motor) . . . . . . . . . . . . . . . . . . . . . . 7.3.122-Speed Motor Shift Slow Or Sluggish

Optional single wheel drive motor) . . . . . . . . . . . . . . . . . . . . . . . 7.3.14

Troubleshooting Guide - Wheel Drive Functions 7.3.2 Form M299





00017


00015


00019


00008



00007

NOTICE



00012


00016


00020

Troubleshooting Guide - Wheel Drive Problems


1) Wheel Drive a) Dirty Hydrostatic ChargeWill Not Work, Oil Filter. See Figure 1.ImplementFunctions OK.

- Replace hydrostatic charge oil filter.

b) Oil Too Cold To Flow Properly - Warm machine up properly beforeThrough The Hydrostatic starting to work. See Section 4.3.Charge Oil FIlter.

c) Control System Malfunction.Control box not sending propersignal to wheel drive pump.See Figure 2.

- Operate the wheel drive to find thechannel it uses on the LH control box(indicated by green light). Perform acontrol output voltage test. See“Implement Control System” test,Section 8.6.


- If output voltage is not ok, theproblem is a failed potentiometerin the foot control. Replace thefailed potentiometer.

Form M299Troubleshooting Guide - Wheel Drive Functions 7.3.4

Figure 1: Hydrostatic Charge Filter

00501


00243



1) Wheel Drive c) Wheel Drive Pump Or Motor - Check case drain return filters forWill Not Work, Failure. metal flakes and perform wheel driveImplementr pump and motor case drain flow tests.Functions OK. See Section 8.3.(Cont’d)

d) Transfer Case Failure. - See Section 7.5.

e) Wrong Hydraulic Oil Viscosity. - Change hydraulic oil viscosity tomatch ambient conditions. See“Appendix A” or hydraulic oil viscositydecal inside the swing-out pumpaccess guard.



2) Wheel Drive a) Dirty Hydrostatic Charge - See Problem #1 in this section.Will Not Work Oil Filter.And No ChargePressure.

b) Charge Pressure Relief Out OfAdjustment. See Figure 2.

- Perform “Wheel Drive ChargePressure” test, Section 8.3.

If correct pressure setting cannot be made, remove the relief cartridge andinspect the seals. Replace the sealsor the relief cartridge if required.

c) Charge Pump Failure.See Figure 3.

- Replace charge pump.

d) Wheel Drive Pump Failure. - Check case drain return filters formetal flakes. Replace wheel drivepump if required.

Figure 3: Hydrostatic Charge Pump

00518

Figure 2: Hydrostatic Charge Pressure Relief

00501



3) Wheel Drive a) Control System Malfunction.Slow Or Control box not sending properSluggish In signal to wheel drive pump.Both See Figure 4.Directions.




b) PCO Relief Out Of Adjustment.See Figure 5.

NOTE: When adjusting PCOpressure be careful not to turnthe adjustment setscrew in tootight. Doing so may damage thecartridge or cause it to stick.

- Perform “Wheel Drive Pump PCOPressure” test, Section 8.3.



00243

Figure 5: Wheel Drive Pump PCO

00674



3) Wheel Drive c) POR Relief Sticking. - Remove the POR relief cartridge andSlow Or See Figure 5. check for a sticking spool. ReplaceSluggish In cartridge if necessary.BothDirections.(Cont’d)

d) Wheel Drive Pump Or - Check case drain return filters forMotor Failure. metal flakes and perform case drain

flow tests. See Section 8.3. Replacewheel drive pump or motor if required.

e) Transfer Case Failure. - See Section 7.5.

f) Leakage In Rotary Manifold - Perform rotarty manifold leakage test.Between Wheel Drive Galleries. Replace seals as required. Contact

your dealer. See Section 8.3



4) Wheel Drive a) Control System Malfunction.Slow Or Control box not sending properSluggish In signal to wheel drive pump.One Direction. See Figure 6.




b) Wheel Drive Pump DirectionalRelief Out Of Adjustment.See Figure 7.

- Perform “Wheel Drive PumpDirectional Relief Pressure” test,Section 8.3.



00243

Figure 7: Wheel Drive PumpHigh Pressure Reliefs

00673



4) Wheel Drive c) EP Solenoid Coil Malfunction.Slow Or See Figure 8.Sluggish InOne Direction.(Cont’d)

- Swap suspect coil with the other EPsolenoid coil and try function again.Replace suspect EP solenoid coil if required.

d) Wheel Drive Pump Or - Check case drain return filters forMotor Failure. metal flakes and perform case drain

flow tests. See Section 8.3. Replacewheel drive pump or motor if required.

e) Leakage In Rotary Manifold - Contact your dealer.Between Wheel Drive Galleries.

f) Loop Flushing Check Valve - Contact your dealer.

5) Failure Of a) Hose Fitting Blows Off. - Hose fitting crimped incorrectly.High Pressure Replace hose. Be sure hose fittingsDriveline Hose. are crimped to the hose and fitting

manufacturer’s specifications.

b) Burst Hose. - Replace hose. Be sure hose is theproper 6-wire spiral with a minimumworking pressure of 6500 PSI(45 Mpa).

Figure 8: EP Solenoid Coil

00675



6) Machine a) Foot Control Valve Malfunction.Creeps In Foot Control Valve not returning toNeutral. the centered, neutral position

when released. See Figure 9.

- Remove foot control valve and checkfor correct motion. Replace footcontrol valve if required.

c) Wheel Drive Pump Stroke - The stroke control valve may be wornControl Valve Worn. and not holding the pump in a neutral

condition. Perform “Wheel DrivePump Null” adjustment, Section 8.3.

Figure 9: Foot Control Valve

00277



7) Wheel Drive a) No Power At Max DisplacementMaximum Lock Solenoid Coil.Displacement See Figure 10.Lock Will NotEngage.(Standard dualwheel drivemotors)

- Check for power at solenoid coil. Ifno power, replace max displacementlock rocker switch in dash panel.

b) Max Displacement Lock - Check continuity of coil with ohmSolenoid Valve Malfunction meter. See “Upper & Lower SolenoidSee Figure 10. Manifold Coil” test, Section 8.6.

Replace coil if required.

- Remove cartridge. Check forcontamination or damaged seals.Replace seals or cartridge if required.

c) Stuck Or Damaged Shift Spool.See Figure 11.

- Remove shift control end cap, shiftspool housing, and shift spool. Checkfor damage to the spool housing andspool. Be sure spool moves freely inthe housing. Replace the spool orspool housing if required.

NOTE: Shift control end cap is underspring pressure. Remove cap slowly.

d) Internal Damage to Wheel Drive - Contact your dealer.Motor.

Figure 10: Max Displacement Lock Solenoid(Blue wire in harness)

00519

Figure 11: Wheel Drive Motor ShiftSpool & Spool Housing

00474



8) 2-Speed Motor a) No Power At 2-Speed ShiftShift Will Not Solenoid Coil. See Figure 12.Work.(Optional singlewheel drivemotor)

- Check for power at solenoid coil. Ifno power, replace 2-speed shift rockerswitch in dash panel.

b) 2-Speed Shift Solenoid Valve - Check continuity of coil with ohmMalfunction. See Figure 12 meter. See “Upper & Lower Solenoid

Manifold Coil” test, Section 8.6.Replace coil if required.

- Remove cartridge. Check forcontamination or damaged seals.Replace seals or cartridge if required.

c) Stuck Or Damaged Shift Spool.See Figure 13.

- Remove shift control end cap, shiftspool housing, and shift spool. Checkfor damage to the spool housing andspool. Be sure spool moves freely inthe housing. Replace the spool orspool housing if required.

NOTE: Shift control end cap is underspring pressure. Remove cap slowly.

d) Internal Damage to Wheel Drive - Contact your dealer.Motor.

Figure 12: Max Displacement Lock Solenoid(Blue wire in harness)

00519


00474



9) 2-Speed Motor a) Sticking Shift Spool Or PluggedShift Slow Or Spool Housing Orifice.Sluggish. See Figure 14.(Optional singlewheel drivemotor)

- Remove shift control end cap, shiftspool housing, and shift spool. Checkfor debris plugging the spool housingand be sure spool moves freely inthe housing. Clean or replace thespool or spool housing if required.

NOTE: The shift control end cap isunder spring pressure. Remove capslowly.


00474

Troubleshooting Guide - Engine Problems7.4.1Form M274

Section 7.4

Troubleshooting Guide -Engine Problems

NOTE: See the engine manufacturer’s manual shipped with the machine formore detailed troubleshooting procedures.


Troubleshooting Guide - Engine Problems:Engine Stalls At Start-Up, Turns Over Hard . . . . . . . . . . . . . . . . . . 7.4.4Engine Stalls Easily During Normal Operation . . . . . . . . . . . . . . . . 7.4.6Engine Loses Power After Running For A Short TIme . . . . . . . . . . 7.4.8Engine Labors Excessively While Using Wheel Drive . . . . . . . . . . 7.4.8Engine Surges Or “Hunts” Even When Not Operating A Function . 7.4.9

Troubleshooting Guide - Engine Problems 7.4.2 Form M274





00017


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00008



00007

NOTICE



00012


00016


00020

Troubleshooting Guide - Engine Problems


1) Engine Stalls a) Improper OIls Used In Gearbox, - Use proper oils for your ambientAt Start-Up, Hydraulics, Or Engine For conditions and follow the cold weatherTurns Over Ambient Temperatures. starting instructions in Section 4.1.Hard.

b) Incorrect Throttle Position For - Set throttle control to 1/3 range forEngine Start. engine start.

c) Wheel Drive Pump Is On-StrokeWhile Engine Is Cranking.

- Depress and hold the pump destrokeswitch while cranking the engine tohold the wheel drive pump in destrokewhile the engine starts. Release afterstarting. See Figure 1.

d) Fuel System: Fuel Lift PumpMalfunction. See Figure 2.

- Be sure the electrical fuel lift pumphas a good electrical ground andcheck fuel pump calibration. Seeengine manufacturer’s manualsshipped with machine. Replaceelectrical fuel lift pump if required.

Form M274Troubleshooting Guide - Engine Problems 7.4.4

Figure 1: Pump Destroke Switch (Typical)

00397

Figure 2: Fuel Lift Pump (Typical)

00000


.PROBLEM PROBABLE CAUSE ACTION

1) Engine Stalls e) Fuel System: Air Trapped in - Check for air leaks in fuel suction lineAt Start-Up, Fuel System. around hose connections. RepairTurns Over if found.Hard.(Cont’d) - Bleed fuel system. See engine

manufacturer’s manuals shipped withmachine.

f) Fuel System: Contamination - Flush fuel suction line.in fuel suction line.

g) Fuel Return Check Valve StuckOpen Or Failed. See Figure 3.

- Remove check valve and inspect fordebris or damage. Clean check valveor replace if required.

h) No Power To Fuel Shut-OffSolenoid Holding Coil.See Figure 4.

- Check for power at the fuel shut-offsolenoid hold coil. Inspect for loosewire connections. Replace fuelshut-off solenoid if required.

i) Engine Malfunction. - Contact your dealer.

Figure 3: Fuel Return Check Valve(Caterpillar Engines Only)

00475

Figure 4: Fuel Shut-Off Solenoid (Typical)

00376

Fuel SedimentBowl Located On

LH Side OfEngine



2) Engine Stalls a) Dirty air filter elements. - Clean or change air filter elements.Easily During See Section 5.6.NormalOperation.

b) Collapsed Or Plugged Muffler. - Inspect muffler. Replace muffler ifrequired.

c) Fuel System: Dirty Fuel Filters. - Change fuel filters. See Section 5.5.

d) Fuel System: Air Trapped in - Check for air leaks in fuel suction lineFuel System. around hose connections. Repair

if found.

- Bleed fuel system. See enginemanufacturer’s manuals shipped withmachine.

e) Fuel System: Fuel Line. - Check for a kinked fuel lines or debrisRestriction. plugging the fuel tank vent line where

it exits near the A/C condenser fans.

f) Fuel System: Contamination - Flush fuel suction line.in fuel suction line.

g) Fuel System: Fuel pump timing - Time fuel pump to engine. See engineout of adjustment. manufacturer’s manuals shipped with

machine.

h) Fuel System: Fuel Lift PumpMalfunction. See Figure 5.



00000



2) Engine Stalls i) Loose Fuel Shut-OffEasily During Solenoid Wire Connection.Normal See Figure 6.Operation.(Cont’d)

- Check for loose wire connections atthe fuel shut-off solenoid. Replacefuel shut-off solenoid if required.

j) Wheel Drive Pump POR Or - Check wheel drive pump pressure High Pressure Relief Settings settings. See Section 8.3.Out Of Adjustment.

k) Wheel Drive Pump POR Or - Check wheel drive pump pressure High Pressure Relief Settings settings. See Section 8.3.Out Of Adjustment.

l) Implement Pump POR Pressure - Check implement pump pressureSettings Out Of Adjustment. settings. See Section 8.2.

m) Main Control Valve Port Relief - Check main control valve port reliefSetting Out Of Adjustment. pressure settings. See Section 8.2.

n) Intake And/Or Exhaust Valves - Adjust intake and exhaust valves.Out Of Adjustment. See engine manufacturer’s manuals

shipped with machine.

o) Intake Or Exhaust Manifold - Replace gasket. See engineGasket Leaking. manufacturer’s manuals shipped with

machine.

p) Engine Malfunction. - Contact your dealer.

Figure 6: Fuel Shut-Off Solenoid (Typical)

00376



3) Engine Loses a) Dirty Fuel Filters. - Change fuel filters. See Section 5.5.Power AfterRunning ForA Short Time.

b) Fuel Tank Vent Line Restriction. - Check for a kinked fuel tank vent line or debris plugging the line where itexits near the A/C condenser fans.

NOTE: Other indications of a pluggedfuel tank vent line are suction on thefuel tank when the fill cap is removedor the fuel filters partially full whenremoved.

c) Wet Air Filter Elements. - Remove air filter elements andinspect. Allow elements to dry orreplace if required.

4) Engine Labors a) Wheel Brakes Not Fully - Be sure brakes are fully disengaged.Excessively, Released.While UsingWheel Drive.

b) Dirty Air Cleaner Elements. - Clean or replace air cleaner elementsSee Section 5.6.

c) Dirty Fuel Filter(s). - Change fuel filters. See Section 5.5.

d) Fuel Lift Pump Malfunction.See Figure 7.


e) Fuel Injector Pump Malfunction. - Contact your dealer.


00000



5) Engine Surges a) Air Trapped In Fuel System. - Check for air leaks in fuel suction lineOr “Hunts” around hose connections. RepairEven When Not if found.Operating AFunction. - Bleed fuel system. See engine

manufacturer’s manuals shipped withmachine.

b) Contamination In Fuel Suction - Flush fuel suction line.Line.

c) Engine Malfunction. - Contact your dealer.

d) Engine Idle Or Surge Screws - Contact your dealer.Out Of Adjustment.

Troubleshooting Guide - Engine Problems Form M274

NOTES

Troubleshooting Guide - General Electrical Problems7.6.1Form M146

Section 7.6

Troubleshooting Guide -General Electrical Problems


Troubleshooting Guide - General Electrical Problems:Engine Will Not Start And No Electrical Will Work . . . . . . . . . . . . . 7.6.4Engine Will Not Start Other Electrical OK . . . . . . . . . . . . . . . . . . . 7.6.5Starter Turns, But Engine Will Not . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.6Starter Motor Continues To Run After Engine Starts . . . . . . . . . . . 7.6.7Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.8Voltmeter In Dash Showing Under-Voltage Condition . . . . . . . . . . 7.6.8Voltmeter In Dash Showing Over-Voltage Condition . . . . . . . . . . . 7.6.8Lights Will Not Work, All Other Electrical OK . . . . . . . . . . . . . . . . . 7.6.9Electric Fill Pump Will Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.10Warning Alarm Will Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.12Warning Alarm Buzzes, No Indicator Lights . . . . . . . . . . . . . . . . . . 7.6.13Hourmeter Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.14

Troubleshooting Guide - General Electrical Problems 7.6.2 Form M146





00017


00015


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NOTICE



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00020

Troubleshooting Guide - General Electrical Problems


1) Engine Will Not a) Master Electrical DisconnectStart And No Switch Turned Off. Electrical Will See Figure 1.Work.

- Turn the master electrical disconnectswitch to the “ON” position.

b) Battery Cables Loose Or - Clean battery cables and posts.Corroded. Tighten all connections.

c) Battery Has Low Electrolyte - Check and restore battery electrolyteLevel. levels. See Section 5.7.

d) Battery Is Dead Or Frozen. - Replace battery.

Form M146Troubleshooting Guide - General Electrical Problems 7.6.4

Figure 1: Master ElectricalDisconnect Switch

00049



2) Engine Will Not a) Low Battery Voltage. - Perform “Battery Voltage Test”,Start, Other Section 8.6.Electrical OK.

b) Battery Cables Loose Or - Clean battery cables and posts.Corroded. Tighten all connections.

c) Battery Has Low Electrolyte - Check and restore battery electrolyteLevel. levels. See Section 5.7.

d) Ignition Switch Malfunction.See Figure 2.

- Check for power at the “S” terminal ofthe ignition switch. See “IgnitionSwitch Continuity & Voltage Test”,Section 8.6. Replace ignition switchif required.

e) Starter Relay Malfunction.See Figure 3.

- Check for power at the “S” terminal(orange wire) of the starter relay onthe engine terminal strip. Replacestarter relay if required.

f) Starter Malfunction. - Repair or replace starter.

Figure 2: Ignition Switch (Typical)

00395

Figure 3: Starter Relay (Typical)

00416



3) Starter Turns, a) Failed Starter Bendix Drive.But Engine See Figure 4.Does Not.

- Remove starter. Repair bendix driveor replace starter if required.

b) Damaged Starter Pinion Gear.See Figure 5.

- Remove starter. Repair pinion gearor replace starter if required.

c) Engine Flywheel Gear TeethBroken. See Figure 6.

- Remove starter and check engine flywheel gear teeth. If damaged, replace engine flywheel gear.

Figure 4: Starter Bendix Drive (Typical)

00476

Figure 5: Starter Pinion Gear (Typical)

00476

Figure 6: Flywheel Teeth (Typical)

00415



4) Starter Motor a) Starter Relay Sticks Closed.Continues To See Figure 7.Run AfterEngine Starts.

- Tap on the starter relay. If thestarter releases, replace the starterrelay.

b) Starter Pinion Gear Not.Disengaging Flywheel Gear.See Figure 8.

- Tap on the starter. If the pinion gearreleases, repair or replace the starter.

c) Ignition Switch StickingSee Figure 9.

- Perform “Ignition Switch Continuity& Voltage Test”, Section 8.6. Replaceignition switch if required.

Figure 8: Starter Pinion Gear (Typical)

00476

Figure 9: Flywheel Teeth (Typical)

00415

Figure 7: Starter Solenoid (Typical)

00416



5) Noisy a) Worn Alternator Belt. - Replace alternator belt and cleanAlternator. pulley shives.

b) Pulley Mis-Alignment. - Align Pulleys.

c) Worn Alternator Bearings. - Remove alternator belt and spinalternator pulley by hand. If the pulleyspins hard, has excessive play, ordoes not spin freely, repair or replacealternator.

d) Alternator Malfunction. - Repair or replace alternator.

6) Voltmeter In a) Worn Alternator Belt. - Replace alternator belt and cleanDash Showing pulley shives.Under-VoltageCondition.

b) Engine RPM Excessively. - Perform “Engine RPM” test,Low. Section 8.4.

c) Poor Ground Connection On - Inspect all ground wires for looseAlternator, Starter, Or Battery. connections.


7) Voltmeter In a) Shorted Battery. - Battery plates may be loose or haveDash Showing debris on them causing a short.Over-Voltage Perform “Battery Voltage” test,Condition. Section 8.6.

b) Shorted Wiring. - Disconnect wiring circuits one at atime until the shorted circuit is found.Inspect for loose connections, etc.Repair or replace components asrequired.

c) Dust, Dirt, Or Debris Shorting - Remove and clean alternator.Out Alternator. Replace alternator if required.




8) Lights Do Not a) Exterior Lights 50 Amp CircuitWork, All Other Breaker Blown. See Figure 10.Electrical OK.

- With the machine cold, check forcontinuity across the exterior lights50 Amp circuit breaker located on theengine terminal strip on the RH side ofthe engine. Replace the exterior lightscircuit breaker if required.

NOTE: If the exterior lights circuitbreaker keeps blowing, remove anynon-factory installed lights that may becausing an overload condition.

b) Exterior Light SwitchMalfunction.

- Test the exterior light rocker switch inthe dash by checking for power at the“S” terminal (white wire) on the lightrelay when the light switch is in the“ON” position. See Figure 11.

Replace the exterior light switch ifrequired.

c) Light Relay Malfunction. - Check for power across the light relaySee Figure 11. when the exterior light switch is in the

“ON” position. Replace the light relayif required.

Figure 11: Light Relay Under The Dash

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Figure 10: Exterior Lights Circuit Breaker

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9) Electric Oil FIll a) Fill Pump 50 Amp CircuitPump Will Not Breaker Blown. See Figure 12.Work.

- With the machine cold, check forcontinuity across the fill pump 50 Ampcircuit breaker located on the engineterminal strip on the RH side of theengine. Replace the fill pump circuitbreaker if required.

b) Fill Pump Activation SwitchMalfunction. See Figure 13.

- Checking for power across the fillpump activation switch (located nearthe left rear engine mount) while it isheld in the “ON” position. Replace thefill pump activation switch if required.

Figure 13: Fill Pump Activation Switch

00102

Figure 12: Fill Pump Circuit Breaker

00418



9) Electric Oil FIll c) Fill Pump Relay Malfunction.Pump Will Not See Figure 14.Work. (Cont’d)

- Check for power across the fill pumprelay when the exterior light switch isin the “ON” position. Replace the lightrelay if required.

d) Loose Wire Connection. - Check for loose wire connection in thefill pump circuit, especially ground wireconnections. Repair if found.

e) Fill Pump Motor Malfunction. - Repair or replace fill pump motor.

Figure 14: Fill Pump Relay

00418



10) Warning a) No Power To Warning Alarm.Alarm Will Not See Figure 15.Operate.

- Check for power at the warning alarm.Repair wiring if required.

b) Warning Alarm Malfunction. - Remove warning alarm from dash andSee Figure 15. test with an ohm meter. Replace

warning alarm if required.

c) Warning Circuit Diode Failure.See Figure 16.

- Locate and replace the diode in theaffected warning circuit. Diodes arelocated under the dash and are red incolor with green and black wireleads. It is best to trace the greenwire to disconnect the diode at theaffected circuit gauge or indicator.

Figure 16: Warning Circuit Diodes (Typical)

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Figure 15: Warning Alarm (Typical)

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11) Warning a) Warning Circuit DiodeAlarm Buzzes Malfunction. See Figure 17.Lightly, NoIndicator Light

- Locate the warning diodes under thedash. Diodes are red in color withgreen and black wire leads.Disconnect the diodes one at a time atits gauge or indicator until the alarmbuzzing stops. Replace the diode thatstopped the buzzing when it wasdisconnected.

b) Warning Alarm Malfunction.See Figure 18.

- Remove warning alarm from dash andtest with an ohm meter. Replacewarning alarm if required.

Figure 17 Warning Circuit Diodes (Typical)

00445

Figure 18: Warning Alarm (Typical)

00051



12) Hourmeter a) No Power To Hourmeter.Does Not Work. See Figure 19.

- Check for power at the hourmeterwhen the ignition switch is in the “ON”position. Repair wiring if required.

b) Hourmeter Malfunction. - Remove hourmeter from dash andSee Figure 19. test with an ohm meter. Replace

hourmeter if required.

Figure 19 Hourmeter (Typical)

00053

NOTES

Troubleshooting Guide - Air Conditioner / Heater Problems7.7.1Form M147

Section 7.7

Troubleshooting Guide -Air Conditioner / Heater Problems


Troubleshooting Guide - Air Conditioner / Heater Problems:Both Air Conditioner And Heater Will Not Work . . . . . . . . . . . . . . . 7.7.4Blower Fan Does Not Work Properly . . . . . . . . . . . . . . . . . . . . . . 7.7.6Air Conditioner Works, But No Cold Air . . . . . . . . . . . . . . . . . . . . . 7.7.8Heater Works, But No Warm Air . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.13

Troubleshooting Guide - Air Conditioner / Heater Problems 7.7.2 Form M147





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00015


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NOTICE



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Troubleshooting Guide - Air Condioner / Heater Problems


1) Both Air a) Air Conditioner / Heater 40 AmpConditioner Circuit Breaker Blown.And Heater See Figure 1.Will Not Work.

- With the machine cold, check forcontinuity across the air conditioner/ heater 40 Amp circuit breakerlocated on the engine terminal stripon the RH side of the engine.Replace the air conditioner / heatercircuit breaker if required.

NOTE: The air conditioner / heatercircuit breaker has the #8 white wireattached.

b) Air Conditioner / Heater ModeSwitch Malfunction.See Figure 2.

- Check mode switch continuity withan ohm meter. Replace the modeswitch if required.

Form M147Troubleshooting Guide - Air Conditioner / Heater Problems 7.7.4

Figure 1: Air Conditioner / HeaterCircuit Breaker

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Figure 2: Air Conditioner / HeaterMode Switch

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1) Both Air c) Air Conditioner / HeaterConditioner Thermostat Control Malfunction.And Heater See Figure 3.Will Not Work.(Cont’d)

- Check thermostat control continuitywith an ohm meter. Replace thethermostat control if required.

d) Automatic Climate ControlSensor Malfunction.See Figure 4.

- Perform the “Automatic ClimateControl Sensor” test, Section 8.7.Replace the automatic climate controlsensor if required.

Figure 3: Air Conditioner / HeaterThermostat Control

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Figure 4: Automatic Climate ControlSensor In Cab Roof

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2) Blower Fan a) Fan Speed Select SwitchDoes Not Work Malfunction. See Figure 5.Properly.

- Check for power at terminal #6 of thefan speed select switch with the airconditioner / heater mode switch ineither position. Replace the fan speedelect switch if no power at terminal #6.

NOTE: It is common with this type ofproblem for only “HI” fan speed towork.

b) Fan Speed Resistor BurnedOut. See Figure 6.

- Check for open cicuits in the fanspeed resistor block with an ohmmeter. Replace resistor if required.

NOTE: The orange wire is power outof the resistor block to the fan motor.


Figure 5: Fan Speed Select Switches

00398

Figure 6: Fan Speed Resistor

00400



2) Blower Fan c) Bad Fan Blower Motor GroundDoes Not Work Wire Connection. See Figure 7.Properly.(Cont’d)

- Inspect fan blower motor ground wireconnections where they terminate ata ground screw mounted in the rearwall of the cab. Tighten or replacewires if required.

d) Fan Blower Motor Malfunction.See Figure 8.

- Inspect fan blower motor. Be sure the fan blower motor and squirrel cagesturn freely. Replace fan blower motorunit if required.

Figure 7: Fan Blower Motor Ground

00404

Figure 8: Fan Blower Motors

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3) Air Conditioner a) Condenser Plugged With Debris.Works, But No See Figure 9.Cold Air.

- Check and clean off condenser.

b) Hot Water Shut-Off Valves At.Engine Open. See Figure 10.

- Close both hot water shut-off valves.at engine.

c) Binary Switch Malfunction.See Figure 11.

- Replace binary switch.

Figure 9: Air Conditioner Condenser

00420

Figure 11: Binary Switch Behind Cab

00422

Figure 10: Hot Water Shut-Off Valve

00012



3) Air Conditioner d) Freon Leak. See Figure 12.Works, But NoCold Air.(Cont’d)

- Locate the drier assembly in the airconditioner / heater enclosure behindthe seat. Check the sight glass forsigns of a freon leak. See Section 5.5.Contact your dealer if a freon leak isindicated or the air conditioner systemrequires recharging.

e) Air Conditioner CompressorDrive Belt Loose.See Figure 13.

- Tighten drive belt. See Section 5.4.

Figure 12: Drier Assembly Sight Glass

00402

Figure 13: Compressor Drive Belt - Typical

00007



3) Air Conditioner f) Condenser Fan RelayWorks, But No Malfunction. See Figure 14.Cold Air.(Cont’d)

- Locate the relay block in the airconditioner / heater enclosure behindthe seat. The condensor fan relay isfound in the lower right socket.Perform a “Relay Block” test for thecondensor fan relay. See Section 8.7.Replace the condensor fan relay ifrequired.

g) Air Conditioner / HeaterThermostat Control Malfunction.See Figure 15.


Figure 14: Condensor Fan Relay

00401


00398



3) Air Conditioner h) Automatic Climate ControlWorks, But No Sensor Malfunction.Cold Air. See Figure 16.(Cont’d)


i) Loose Electrical ConnectionTo Air Conditioner Compressor.See Figure 17.

- Check all electrical connections at theair conditioner compressor, especiallythe ground wire. Tighten any loosewires.

j) Air Conditioner Compressor. - Replace air conditioner compressor.Malfunction. See Figure 17.


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Figure 17: Air Conditioner Compressor(Typical)

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3) Air Conditioner k) Condenser Fan Malfunction.Works, But No See Figure 18.Cold Air.(Cont’d)

- Check for damaged fan blades.Replace fan blades if required.

- Inspect wiring to motor assembly.Tighten any loose connections.

- Inspect motor assembly. Replacemotor if required.

l) Internal Air Conditioner / Heater - Contact your dealer.Unit Malfunction.

Figure 18: Condenser Fans Behind Cab

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4) Heater Works, a) Hot Water Shut-Off Valves AtBut No Warm Engine Closed. See Figure 19.Air.

- Open both hot water shut-off valves.at engine.

b) Hot Water Shut-Off Valve RelayMalfunction. See Figure 20.

- Locate the relay block in the airconditioner / heater enclosure behindthe seat. The hot water shut-off valverelay is found in the upper left socket.Perform a “Relay Block” test for thehot water shut-off valve relay. SeeSection 8.7. Replace the hot watershut-off valve relay if required.

Figure 19: Hot Water Shut-Off Valve

00012

Figure 20: Hot Water Shut-Off Valve Relay

00401


4) Heater Works, c) Water Shut-Off ValveBut No Warm Malfunction. See Figure 21.Air. (Cont’d)

- Be sure the main hot water shut-offvalve is operating correctly. Turnthermostat control to the warmestsetting and check to see if the watershut-off solenoid actuates. Replacethe water shut-off valve if required.

d) Air Conditioner / HeaterThermostat Control Malfunction.See Figure 22.



Figure 21: Main Hot Water Shut-Off Valve

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00398



4) Heater Works, e) Automatic Climate ControlBut No Warm Sensor Malfunction.Air. (Cont’d) See Figure 23.



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Troubleshooting Guide - Air Conditioner / Heater Problems Form M147


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