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Caterpillar 236D3 Troubleshooting

The Cat 236D3 skid steer loader is powered by 203.1 cu.in (3.3L) Caterpillar C3.3B DIT 4-cycle 4-cylinder turbocharged diesel engine with a rated power of 73.2 hp (54.6 kW) at 2400 rpm. The Caterpillar 236D3 is equipped with a two-speed hydrostatic transmission, 80HS continuous roller chains, and 10x16.5 standard tires. The hydraulic system has a pump with fluid flow rate of 20.3 gpm (77 lpm) or 26 gpm (99 lpm). The hydraulic pressure is 3335 psi (230 bar). The skid steer loader has a rated operating capacity of 1800 lbs (820 kg) and tipping load of 3600 lbs (1640 kg). The boom lifting force is 3844 lbs (1743 kg), and bucket breakout force is 5003 lbs (2270 kg).

Engine Troubleshooting

Engine starts up hard or won't start
Air in the fuel lines - Bleed the fuel lines.
Fuel filter element is clogged - Service the filter.
Fuel injection nozzles are clogged or faulty - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is out of adjustment - Correct valve clearance needs to be set.
Fuel injection pump is broken - Replacement or repair required.

Engine starts but immediately stalls
Air cleaner is clogged - Install new air cleaner element.
Fuel filter plugged - Clean the filter or install new filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Dirty or defective injectors - Replace fuel injectors.
Fuel injection pump is defective - Replace injection pump or repair it.

Engine stalls during operation
Engine not warmed up - Warm up the engine.
Fuel filter plugging - Replace the filter element.
Air in fuel tank - Bleed fuel tank.
Clogged injection nozzle - If necessary, replace with a new nozzle.
Incorrect adjustment of fuel injection pump timing - Adjust as recommended.

Engine stops while idle
Incorrect low idle speed adjustment - Correct the settings.
Fuel injection pump malfunctioning - Repair or change injection pump.
Defective fuel injectors - Test and replace fuel injectors if necessary.
Valve clearance is not correct - Correct valve clearance needs to be set.

Engine lacks power
Clogged air filter - Clean or replace element.
Clogged injection nozzle - Service or change injection nozzles.
Insufficient fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Improper valve clearance - Adjust valve clearance.
Low idle speed setting is not correct - Correct the settings.
Dirty fuel hoses or lines - Service fuel lines and hoses.
Cylinder-head gasket is broken - Install new cylinder head gasket.
Piston rings are worn or damaged - Replace the piston rings as required.

Engine overheated
Low coolant level - Add coolant fluid and inspect the cooling system for leaks.
Low engine oil level - Add oil to the engine crankcase.
Dirty radiator core or defective radiator cap - Clean radiator or install new cap.
Fan belt slipping or worn - Change the fan belt.
Engine is under excessive load - Reduce engine load.

Insufficient oil pressure
Low oil level - Add oil to the engine crankcase.
Oil filter is dirty - Service or replace engine oil filter.
Oil grade or viscosity is incorrect - Use the specified type of engine oil.
Crankshaft bearing oil clearance is incorrect - Replace bearings.
Oil pump malfunction - Check and replace if necessary.

Engine knocking sound or abnormal noise
Engine oil insufficient - Check and refill engine oil.
Engine not warmed up - Warm up engine as required.
Incorrect adjustment of fuel injection pump timing - Adjust fuel injection pump as required.
Wrong adjustment of low idle speed - Adjust low idling as recommended.
Clogged or defective injectors - Clean fuel injectors or change it.
Misaligned or faulty connecting rod - Need to replace or align the connecting rod.
Scored or worn pistons - Pistons replacement required.

Drive System Troubleshooting

Drive system does not work in either direction
Hydraulic fluid is insufficient - Check and refill the hydraulic fluid.
Damaged drive chain - Inspect drive chain and replace faulty parts.
Input drive shaft malfunction - Drive shaft need to be replaced or repair.
Relief valve is stuck - Change or repair relief valve.
Hydraulic filter or suction line is plugged - Check, clean, or replace if required.
Defective or worn foot or hand controls - Check and repair as required.
Worn drive motor or pump - Replace or repair faulty component.

Low power
Hydraulic oil filter is plugged - Check, clean, or change as necessary.
Opened or defective relief valve - Replace or close relief valve.
Transmission parts are defective or worn - Inspect and change faulty parts.
Damaged input drive shaft - Replace or service the drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Drive system is overheated
Low hydraulic fluid level - Fill up the hydraulic fluid.
Clogged hydraulic fluid filter - Check, clean, or change as necessary.
Relief valve is damaged - Repair or install a new relief valve.
Damaged drive pump or hydraulic motor - Inspect and replace as necessary.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Drive system is overloaded - Reduce the load.

Drive system is excessively noisy
Incorrect oil viscosity - Use proper oil viscosity.
Air trapped in hydraulic system - Air bleeding is required.
Hydraulic motor or drive pump failure - Repair or replace faulty component.
Mechanical parts of drive system are worn or damaged - Inspect the parts for defect or damage and repair as required.

Hydraulics Troubleshooting

Hydraulic system is overheated
Incorrect hydraulic pressure setting - Correct adjustment is required.
Main relief valve is defective or unadjusted - Replace or set up the relief valve.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Not enough hydraulic oil in the system - Fill the hydraulic system with oil.
Faulty hydraulic oil pump - Replace or repair pump if necessary.

Boom won't lower or raise
Damaged lift controls - Change or repair.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Change or repair hydraulic valve.
Faulty hydraulic cylinder - Replace or repair boom cylinder.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.

Bucket fails to tilt
Bucket tilt controls malfunction - Repair or change.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Defective hydraulic control valve - Install a new valve or repair it.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.

Boom or bucket functions slowly
Faulty hydraulic oil pump - Check the pump performance and replace it if required.
Hydraulic cylinder leaking - Install new cylinder seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Worn or unadjusted hydraulic control valve - Repair or set correctly.
Hydraulic system loosing pressure - Adjust it correctly.

Bucket or boom movements are jerky
Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter element is dirty - Clean or install new filter.
Dirty hydraulic fluid - The fluid must be changed.
Scratched cylinder rod or tube - Replace failed component.

Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Remedy hydraulic leakage or refill oil as necessary.
Clogged hydraulic filter - Service or change hydraulic filter.
Dirty suction line - Need to clean the suction line.
Air trapped in hydraulic pump - Air bleeding is required.
Faulty pump parts - Replace or rebuild the pump.

Electrical Troubleshooting

Battery cannot be charged
Loose or corroded electrical wiring connections - Tighten or service connections.
Battery terminal clamps are defective - Terminal clamps should be changed.
Battery is worn - Battery replacement required.
Worn or loose belt - Belt needs to be adjusted or changed.

Starter cranks slowly
Low battery voltage - Recharge the battery.
Battery is not holding charge - Service battery or change it.
Disconnected wiring or bad battery terminals - Check wiring and clean or replace terminals.

Starter motor is not working
Battery is low or faulty - Charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery capacity - Recharge the battery.
Faulty starter motor - Repair or replace starter.