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Caterpillar 242B Troubleshooting

The Cat 242B skid steer loader is powered by 134.1 cu.in (2.2L) Caterpillar 3024CT 4-cycle 4-cylinder turbocharged liquid cooled diesel engine with a rated power of 57 hp (43 kW) at 2600 rpm. The Cat 242B is equipped with a single-speed or two-speed hydrostatic transmission, wet multi disc brakes, and 10x16.5 or 12x16.5 tires. The hydraulic system has a pump with fluid flow rate of 15.6 gpm (60 lpm). The hydraulic pressure is 3335 psi (230 bar). The skid steer loader has a rated operating capacity of 2000 lbs (907 kg) and tipping load of 4000 lbs (1815 kg). The boom lifting force is 3840 lbs (1742 kg), and bucket breakout force is 4060 lbs (1840 kg).

Engine Troubleshooting

Engine starts hard or doesn't start
Air trapped in fuel system - Bleed air.
Dirty fuel filter - Clean or change the filter.
Clogged or defective injection nozzles - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is out of adjustment - Have it adjusted.
Fuel injection pump is broken - Repair or change injection pump.

Engine starts but stalls immediately
Clogged air cleaner - Clean or change.
Fuel filter element is dirty - 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 - Clean fuel injectors or change it.
Faulty fuel injection pump - Rebuild or install a new injection pump.

Engine stalls while running
Engine is cold - Warm up to required temperature.
Clogged fuel filter - Change the filter element.
Air in fuel tank - Bleed fuel tank.
Faulty fuel injection nozzles - Clean or replace injection nozzles.
Improper setting of fuel injection pump timing - Adjust as recommended.

Engine stops when idle
Wrong adjustment of low idle speed - Test and adjust.
Faulty fuel injection pump - Rebuild or install a new injection pump.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
Valve out of adjustment - Correct valve clearance needs to be set.

Loss of engine power
Dirty air cleaner - Clean or replace element.
Faulty fuel injection nozzles - Install a new kit of correctly balanced nozzles.
Improper fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Incorrect valve clearance - Correct valve clearance.
Incorrect low idle setting - Need to adjust idle speed.
Dirt in the fuel lines or hoses - Fuel lines and hoses need to be cleaned.
Blown cylinder head gasket - Change cylinder head gasket.
Defective or worn piston rings - Piston rings need to be replaced.

Engine overheats
Low coolant level - Refill to the correct level and inspect system for leaks.
Engine oil level low - Add oil to the engine crankcase.
Radiator core is dirty or radiator cap is damaged - Install new cap or clean radiator.
Fan belt slipping or worn - Install new fan belt.
Diesel engine is overloaded - Reduce load on the engine.

Insufficient oil pressure
Not enough oil in the engine - Check oil level and add oil as required.
Clogged oil filter element - Clean or replace engine oil filter element.
Improper type of engine oil - Use oil of correct viscosity.
Crankshaft bearing oil clearance is excessive - Change bearings.
Worn oil pump - Check and replace if necessary.

Engine noise or knocking
Not enough engine oil - Add oil to the engine crankcase.
Engine is not warmed up to the required temperature - Warm up to required temperature.
Fuel injection pump timing is wrong - Check the fuel injection pump timing adjustment.
Too low idle RPM - Normalize low idle speed.
Damaged or clogged injectors - Clean or replace fuel injectors.
Misaligned or defective connecting rod - Connecting rod must be aligned or replaced.
Pistons are scored or worn - Replace the pistons.

Drive System Troubleshooting

Drive system will not operate in either direction
Insufficient hydraulic oil - Need to add oil.
Drive chain is worn - Check drive chain and change defective parts.
Input drive shaft is not working properly - Change or repair.
Relief valve failure - Service or change relief valve.
Dirty hydraulic filter or suction line - Change hydraulic filter or service suction line.
Faulty foot or hand controls - Check and repair as required.
Drive motor or pump is worn - Repair or replace faulty component.

Reduced power
Hydraulic oil filter is dirty - Change or clean hydraulic filter.
Relief valve is defective or open - Close or change relief valve.
Transmission components are faulty or damaged - Inspect and change faulty parts.
Input drive shaft is defective - Service or change faulty drive shaft.
Air in the hydraulic system - Air bleeding is required.

Overheated drive system
Low hydraulic oil level - Need to add oil.
Dirty hydraulic fluid filter - Replace or clean hydraulic filter.
Relief valve is stuck - Rebuild or install a new relief valve.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Hydraulic oil cooler is plugged - Cooling fins need to be cleaned.
Drive system overloaded continuously - Reduce the load.

Drive system is noisy
Wrong oil viscosity - Drain and refill with proper oil.
Air in the hydraulic system - Bleed hydraulic system.
Defective drive pump or hydraulic motor - Change or repair faulty component.
Worn or damaged mechanical parts of drive system - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Main relief valve is damaged or adjusted improperly - Adjust the valve or replace if necessary.
Contaminated hydraulic fluid - Change hydraulic fluid.
Not enough hydraulic fluid in the system - Check and refill the hydraulic fluid.
Hydraulic pump is worn - Repair or change pump if required.

Lift arm fails to drop or lift
Lift controls are faulty - Check and repair as required.
Hydraulic pump malfunction - Repair or change pump if required.
Damaged hydraulic control valve - Repair or change the valve.
Hydraulic cylinder failure - Repair or install a new lift cylinder.
Hydraulic oil level low - Checking hydraulic oil level and add if necessary.

Bucket tilt does not work
Faulty bucket tilt controls - Check and repair as required.
Hydraulic pump failure - Change or repair hydraulic pump if required.
Hydraulic control valve malfunction - Install a new hydraulic valve or repair it.
Broken bucket cylinder - Repair or change cylinder.
Insufficient hydraulic fluid - Fill up the hydraulic fluid.

Boom or bucket functions slowly
Defective hydraulic pump - Test the pump flow rate and install new pump if required.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Low hydraulic fluid level - Add fluid as required.
Hydraulic control valve is faulty or out of adjustment - Repair or set properly.
Hydraulic pressure has dropped - Hydraulic pressure must be set correctly.

Bucket or boom is working jerkily
Air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element is dirty - Service or change the hydraulic filter.
Contaminated hydraulic oil - The oil must be changed.
Scored cylinder tube or rod - Replace failed component.

Hydraulic pump makes excessive noise
Hydraulic system leaking or not enough oil - Top up hydraulic oil or remedy leakage in system.
Clogged hydraulic filter - Clean or replace the filter.
Suction line is dirty - Clean suction line as required.
Air trapped in hydraulic pump - Remove air from hydraulics.
Pump components are worn out - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery does not charge
Electrical cable connections are loose or corroded - Tighten or service connections.
Battery terminal connectors are defective - Terminal connectors need to be changed.
Faulty cell in battery - Change the battery.
Defective or loose belt - Adjust belt tension or change the belt.

Starter motor cranks slow
Low battery capacity - Recharge the battery.
Battery runs out quickly - Battery needs to be serviced or replaced.
Disconnected wires or corroded battery terminals - Check cable connections and change or clean terminals.

Starter will not crank
Battery is low or faulty - Need to charge or replace the battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery power is low - Recharge the battery.
Damaged starter motor - Starter needs to be changed.