Problem 1. Boom will not extend or retract.
Cause : 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 2. Crowd hydraulic system not operating properly. 3. Faulty Crowd cylinder.
Remedy: 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8, “Hydraulic System.” 3. Repair cylinder (Refer to Section 8.11.4, “Cylinder Inspection.”)
Problem 2. Boom will not fully extend.
Cause : 1. Crowd hydraulic system not operating properly.
Remedy: 1. Refer to Section 8, “Hydraulic System.”
Problem 3. Boom shifts to right or left when extending.
Cause : 1. Boom pivot pin improperly shimmed. 2. Incorrect wear pad gap or shimming, or wear pads excessively worn.
Remedy: 1. Re-shim the boom to a maximum total gap of .10″ (2.5 mm) with shims distributed evenly on both sides of the boom pivot pin. 2. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.”
Problem 4. Excessive pivot pin noise and/or wear.
Cause : 1. Insufficient lubrication. 2. Worn bearing(s).
Remedy: 1. Lubricate at regular intervals. (Refer to appropriate owners manual for lubrication points.) Replace worn pins as needed. 2. Replace bearing(s) and lubricate at regular intervals (Refer to appropriate owners manual for lubrication points.)
Problem 5. Boom will not raise or lower.
Cause : 1. Broken hydraulic hoses or tubes and/or connection leaks. 2. Hoist hydraulic system not operating properly. 3. Faulty Hoist cylinders. 4. Seized boom pivot pin bearing.
Remedy: 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8, “Hydraulic System.” 3. Repair cylinder. (Refer to Section 8.11.4, “Cylinder Inspection.”) 4. Replace bearing.
Problem 6. Excessive axle noise while driving.
Cause : 1. 1. Oil level too low. 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 3. Incorrect alignment of ring and pinion gears. 4. Incorrect pinion (input) shaft bearing preload. 5. Worn or damaged bearings. 6. Worn or broken gear teeth. 7. Contamination in the axle.
Remedy: 1. Fill oil to correct level. (Refer to appropriate Operator/Safety Manual.) 2. Drain axle and/or wheel end housings and fill to correct level with Universal Tractor Fluid. (Refer to appropriate Operator/ Safety Manual.) 3. Correct alignment by adding or removing shims as needed. 4. Correct bearing preload by adding or removing shims as needed. 5. Replace bearings as needed. 6. Replace gears as needed. 7. Drain axle and/or wheel end housings and fill to correct level with Universal Tractor Fluid. (Refer to appropriate Operator/ Safety Manual.) 8. Replace damaged parts.
Problem 7. Intermittent noise when traveling.
Cause : 1. Universal joint(s) worn or damaged. 2. Differential ring and/or pinion gears damaged.
Remedy: 1. Repair or replace universal joints as needed. 2. Determine cause and repair as needed.
Problem 8. Vibration or intermittent noise when traveling.
Cause : 1. Drive shaft universal joint assembly(ies) incorrectly tightened. 2. Drive shaft universal joint(s) worn or damaged. 3. Drive shaft(s) damaged/ unbalanced.
Remedy: 1. Tighten capscrews to correct torque. 2. Repair or replace universal joints as needed. 3. Replace drive shaft(s) as needed.
Problem 8. Oil leaking from axle (differential housing and/or axle housings).
Cause : 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 2. Hose fittings loose. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces. 4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces. 5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged. 6. Axle housing mounting nuts and capscrews loose. 7. Differential and/or axle housing(s) damaged.
Remedy: 1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft). 2. Tighten fittings. 3. Replace seal and/or joint coupling fork shaft (axle shaft). 4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the ZF Repair Manuals. 5. Replace o-rings and seals. 6. Tighten housing nuts and capscrews to 390 Nm (288 lb-ft). 7. Replace housing(s) as needed.
Problem 9. Oil leaking from wheel end housing (planet carrier).
Cause : 1. Oil level plugs loose and/or o-rings damaged or missing. 2. O-ring between hub and housing (planet carrier) damaged or missing. 3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces. 4. Housing capscrews loose. 5. Housing (planet carrier) damaged.
Remedy: 1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft). 2. Replace o-ring. 3. Replace seal and/or fork joint shaft. 4. Tighten housing capscrews to 55 Nm (41 lb-ft). 5. Replace housing (planet carrier).
Problem 10.Oil leaking from steering cylinder.
Cause : 1. Hose fittings loose. 2. Steering cylinder o-rings and/or seals worn or damaged. 3. Piston rod seal worn or damaged. 4. Cylinder tube damaged.
Remedy: 1. Tighten fittings. 2. Replace o-rings and seals. 3. Replace piston rod seal. 4. Replace cylinder tube.
Problem 11. Axle overheating.
Cause : 1. Oil level too high. 2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.
Remedy: 1. Fill oil to correct level with Akros Multi FCT Tractor / Hydraulic Fluid. (Refer to appropriate Operator/Safety Manual.) 2. Drain axle and fill to correct level with Akros Multi FCT Tractor / Hydraulic Fluid. (Refer to approp
Problem 12. High steering effort required.
Cause : 1. Steering (hydraulic) system not operating properly. 2. Excessive joint housing swivel bearing preload. 3. Worn or damaged swivel bearings.
Remedy: 1. Refer to Section 8.11.7, “Steering Cylinders.” 2. Correct bearing preload by adding or removing shims as needed. 3. Replace swivel bearings as needed.
Problem 13. Slow steering response.
Cause : 1. Steering (hydraulic) system not operating properly. 2. Steering cylinder leaking internally.
Remedy: 1. Refer to Section 8.11.7, “Steering Cylinders.” 2. Repair or replace steering cylinder as needed.
Problem 14. Excessive noise when brakes are engaged.
Cause :1. Brake discs worn. 2. Brake discs damaged.
Remedy: 1. Check brake discs for wear. (Refer to appropriate Operator/ Safety Manual.) 2. Replace brake discs.
Problem 15. Brakes will not engage.
Cause : 1. Brake (hydraulic) system not operating properly. 2. Brake piston o-rings and seals damaged (leaking).
Remedy: 1. Refer to Section 8.11.7, “Steering Cylinders.” 2. Replace o-rings and seals
Problem 16. Brakes will not hold the machine or braking power reduced.
Cause : 1. Brake discs worn. 2. Brake (hydraulic) system not operating properly. 3. Brake piston o-rings and seals damaged (leaking).
Remedy: 1. Check brake discs for wear. (Refer to appropriate Operator/ Safety Manual.) 2. Refer to Section 8.11.7, “Steering Cylinders.” 3. Replace o-rings and seals.
Problem 17. Differential ring gear teeth broken on the heel of the tooth.
Cause : 1. Incorrect alignment of ring and pinion gears (excessive play). 2. Incorrect pinion (input) shaft bearing preload.
Remedy: • Replace ring and pinion gears. • Adjust ring and pinion alignment and bearing preload as described in the D-S Repair Manuals.
Problem 18. Differential ring gear teeth broken on the toe of the tooth.
Cause : 1. Incorrect alignment of ring and pinion gears (insufficient play). 2. Incorrect pinion (input) shaft bearing preload.
Remedy: Replace ring and pinions gears. • Adjust ring and pinion alignment and bearing preload as described in the D-S Repair Manuals.
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