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Caterpillar 239D3 Troubleshooting

The Caterpillar 239D3 compact track loader driveline system components: a 134.1 cu.in (2.2L) Cat C2.2T 4-cylinder turbo diesel engine with a rated power of 65.8 hp (49.1 kW), and 2-speed hydro transmission. The hydraulic system has a pump with a rated flow of 18 gpm (69 lpm) or 26 gpm (99 lpm). The system pressure is 3335 psi (230 bar). The Cat 239D3 is equipped with radial-lift boom, fully suspension undercarriage, and 12.6" (320 mm) or 15.7" (400 mm) rubber tracks. The loader has a maximum lift height of 111.2" (2.83 m) to hinge pin and dump height of 81" (2.06 m). The rated operating capacity is 1530 lbs (695 kg), and tipping load is 4370 lbs (1990 kg).

Engine Troubleshooting

Engine starts up hard or will not start
There is air in the fuel system - Bleed the system.
Fuel filter plugging - Clean the filter or install new filter element.
Burnt or clogged injection nozzle - Check and replace nozzles if required.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is wrong - Correct valve clearance needs to be set.
Fuel injection pump is damaged - Rebuild or change fuel pump.

Diesel starts and stops
Air cleaner is dirty - Clean or change cleaner.
Fuel filter element is clogged - Replace the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are dirty or defective - Replace fuel injectors.
Fuel injection pump failure - Rebuild or replace pump.

Engine stops running suddenly
Coolant temperature is low - Warm up engine as required.
Clogged fuel filter - Change filter element.
Air in fuel tank - Bleed fuel tank.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Wrong setting of fuel injection pump timing - Set up as recommended.

Engine stalls when idling
Incorrectly adjusted low idle speed - Correct the settings.
Fuel injection pump is faulty - Repair or replace injection pump.
Fuel injector fault - Clean fuel injectors or change it.
Valve clearance is wrong - Have it adjusted.

Low engine power
Dirty air filter - Service or replace the air filter.
Faulty or dirty injection nozzles - Clean or replace injection nozzles.
Fuel injection pressure is wrong - Adjust to correct pressure.
Improper valve clearance - Adjustment procedure required.
Incorrect low idle setting - Adjust low idling as recommended.
Fuel lines or hoses clogging - Fuel hoses and lines must be clean.
Damaged cylinder-head gasket - Replace the gasket as required.
Damaged or leaking piston rings - Piston rings need to be replaced.

Engine is overheated
Engine coolant is insufficient - Add coolant and check the components of cooling system.
Not enough engine oil - Checking oil level and add if necessary.
Dirty radiator fins or faulty radiator cap - Clean radiator or change cap.
Excessive wear of the fan belt - The fan belt needs to be replaced.
Diesel engine overloaded - Reduce load on the engine.

Low oil pressure
Low oil level - Add oil as required.
Oil filter is dirty - Clean or replace engine oil filter element.
Oil grade or viscosity is incorrect - Use proper viscosity oil.
Excessive crankshaft bearing oil clearance - Install new bearings.
Oil pump is defective - Replace as required.

Abnormal engine knocking or noise
Engine oil level is low - Fill up the engine oil.
Low coolant temperature - Warm up to required temperature.
Fuel injection pump timing is wrong - Set the fuel pump timing correctly.
Incorrectly set low idle speed - Adjust as required.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Connecting rod is defective or misaligned - Connecting rod must be aligned or replaced.
Broken or worn pistons - Have pistons replaced.

Drive System Troubleshooting

Drive system will not operate in either direction
Insufficient hydraulic oil - Need to add oil.
Undercarriage tracks are defective or jammed - Repair or remove jamming.
Relief valve is not working correctly - Repair or replace.
Hydraulic filter or suction line is dirty - Clean suction line or change hydraulic filter.
Defective or worn foot or hand controls - Repair or replace.
Defective drive pump or motor - Check and repair if required.

Machine won't move straight or moves jerky
Jammed or damaged track mechanism - Remove jamming or repair tracks.
Tracks are faulty or sagging - Repair tracks or correct track sag with tension.
Foreign objects, debris, or dirt jammed in track frame - Remove foreign objects or debris and clean undercarriage track frame.

Low power
Clogged hydraulic oil filter - Check, clean, or replace as required.
Opened or defective relief valve - Close or change relief valve.
Transmission parts are damaged or faulty - Check and replace faulty components.
Input drive shaft is damaged - Rebuild or change the shaft.
Air in hydraulic system - Air bleeding is required.

Drive system is overheated
Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Clogged hydraulic fluid filter - Change or service hydraulic filter.
Relief valve is worn or damaged - Repair or change.
Hydraulic motor or drive pump is defective - Check and repair if required.
Hydraulic oil cooler is plugged - Clean cooling fins as required.
Transmission overloading - Load should be reduced.

Excessive noise
Oil viscosity is incorrect - Use correct oil viscosity.
Air in hydraulic system - Air bleeding is required.
Damaged drive pump or hydraulic motor - Inspect and replace as necessary.
Defective or worn mechanical parts of drive system - Check the parts for defect or damage and change if required.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Correct adjustment is required.
Unadjusted or defective main relief valve - Adjust or replace the relief valve.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Need to add fluid.
Hydraulic pump is defective - Replace or repair pump if necessary.

Lift arm won't raise or lower
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve is defective - Repair or replace the valve.
Hydraulic cylinder is defective - Repair or change hydraulic cylinder.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Bucket won't move
Bucket controls are faulty - Repair or change.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Repair or replace hydraulic valve.
Hydraulic bucket cylinder is broken - Repair or replace cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Slow bucket or lift arm operation
Hydraulic pump is defective - Check pump flow and install new pump if necessary.
Hydraulic cylinder leaking - Repair leak by replacing the seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is defective or set improper - Set properly or repair.
Low hydraulic pressure - Hydraulic pressure must be set correctly.

Lift arm or bucket is moving jerkily
Air trapped in hydraulic system - Air bleeding is required.
Dirty hydraulic oil filter element - Change or clean oil filter.
Hydraulic oil contamination - Change hydraulic oil.
Scratched cylinder rod or tube - Replace damaged component.

Hydraulic pump is noisy
Hydraulic leakage or lack of oil - Correct hydraulic leaks or top up oil as needed.
Clogged hydraulic filter - Service or change hydraulic filter.
Suction line is clogged - Suction line must be serviced.
Air trapped in hydraulic pump - Remove air from hydraulics.
Damaged pump parts - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Loose or corroded cable connections - Tighten or clean electrical wiring connections.
Faulty battery terminal clamps - Terminal clamps need to be replaced.
Dead cell in battery - Replace the battery.
Defective or loose belt - Change belt or adjust belt tension.

Starter cranks slow
Low battery voltage - Battery is drained, charge it.
Battery discharges quickly - Service or change the battery.
Faulty battery terminals or disconnected cables - Check wiring connections and replace or clean terminals.

Starter doesn't crank
Battery is low or faulty - Battery needs to be recharged or replaced.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery voltage is low - Battery is drained, recharge it.
Faulty starter motor - Repair or change starter.