IT28G Hydraulic System Issue: Slow Mast Lowering and Joystick Control Failure

[MikePhua]

The user reports that the IT28G loader is experiencing slow mast lowering and cannot use the joystick to lower the mast. This issue affects the machine's efficiency, especially in tasks requiring quick mast adjustments. Slow mast movement or control failure can delay operations and impact productivity.
Common Causes

1. Insufficient or Contaminated Hydraulic Fluid
   If the hydraulic fluid is low or contaminated, it can cause improper functioning of the hydraulic system, especially in the mast lowering and control system. Contaminants can clog the valves or damage the pump, resulting in slow or faulty mast movement.
   
2. Hydraulic Pump Malfunction
   A faulty hydraulic pump is another common cause of slow mast movement. If the pump is worn out or not operating efficiently, it may not generate sufficient pressure, leading to delayed mast movement.
   
3. Hydraulic Valve Issues
   Malfunctions in hydraulic control valves (such as proportional or flow control valves) can cause irregular fluid flow. Blocked or worn-out valves may fail to control the mast lowering function properly, leading to slow or erratic movement.
   
4. Joystick Control System Failure
   The joystick system may have issues such as electrical faults, sensor problems, or signal transmission failures. If the joystick is not sending correct signals to the hydraulic valves, the mast will not respond to the joystick commands, preventing lowering.
   
5. Hydraulic Line Leaks
   Leaking hydraulic lines can lead to reduced pressure in the hydraulic system, preventing proper fluid flow and resulting in slow mast lowering. Leaks can occur at hose connections, seals, or fittings.
   

Troubleshooting Steps

1. Check Hydraulic Fluid Levels and Quality
   The first step is to check the hydraulic fluid level. Ensure the fluid is at the correct level and of good quality. If the fluid is contaminated, it should be drained and replaced with the recommended type of hydraulic oil. Also, replace any clogged filters to ensure optimal fluid flow.
   
2. Inspect the Hydraulic Pump
   Check the hydraulic pump for proper functioning. Use a pressure gauge to verify if the pump is providing the necessary pressure. If the pump is malfunctioning or showing signs of wear, it may need to be repaired or replaced.
   
3. Examine Hydraulic Valves and Controls
   Inspect the control valves responsible for mast movement. Look for any blockages, leaks, or signs of wear. Ensure that the joystick is sending the correct signals and that the valves are responding to these commands. Clean or replace faulty valves as needed.
   
4. Check Joystick Control System
   Inspect the joystick control system for electrical issues, including wiring problems or faulty sensors. Verify that the control signals are properly transmitted from the joystick to the hydraulic valves. Use diagnostic tools to check for communication errors in the system.
   
5. Inspect Hydraulic Lines for Leaks
   Check all hydraulic lines for leaks, especially around connections and fittings. Any sign of fluid leakage should be addressed immediately by tightening connections or replacing damaged hoses.
   

Solutions

1. Replace or Top Up Hydraulic Fluid
   If the fluid level is low or the oil is contaminated, replace the hydraulic fluid and ensure the fluid is clean. Replace any filters to ensure proper filtration of the fluid.
   
2. Repair or Replace the Hydraulic Pump
   If the hydraulic pump is found to be faulty, repair or replace it. Ensure the pump is providing sufficient pressure for the mast lowering operation.
   
3. Repair or Replace Hydraulic Valves
   If the valves are blocked, damaged, or malfunctioning, clean or replace them. Ensure that the valves are properly regulating the fluid flow to the mast.
   
4. Repair Joystick Control System
   If the joystick control system is malfunctioning, inspect the electrical components, wiring, and sensors. Repair or replace faulty parts to restore proper control.
   
5. Fix Hydraulic Line Leaks
   Repair or replace any leaking hydraulic lines. Ensure that all connections are properly tightened to prevent further leaks and maintain optimal system pressure.
   

Preventive Measures

1. Regularly Check Hydraulic Fluid Levels and Quality
   Periodically check the hydraulic fluid levels and replace the fluid as needed. Keep the fluid clean by replacing filters regularly and using high-quality oil to prevent contamination.
   
2. Maintain the Hydraulic Pump and Valves
   Perform regular maintenance on the hydraulic pump and valves to ensure they are functioning properly. Inspect for wear, damage, or signs of leakage and replace parts as needed.
   
3. Inspect the Joystick Control System
   Regularly inspect the joystick control system for electrical faults and ensure proper signal transmission. Replace any damaged wires or faulty sensors to avoid control issues.
   
4. Inspect Hydraulic Lines and Fittings
   Regularly check hydraulic lines and fittings for signs of wear or leaks. Tighten connections and replace damaged hoses to prevent fluid loss and pressure issues.
   

Conclusion
When the IT28G loader experiences slow mast lowering or joystick control failure, it is essential to check the hydraulic fluid, hydraulic pump, control valves, joystick control system, and hydraulic lines. By following a thorough troubleshooting process, users can identify and resolve the issue effectively. Regular maintenance and inspections will help prevent future hydraulic system problems, ensuring smooth and efficient loader operation.