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Caterpillar 262D3 Troubleshooting

The Caterpillar 262D3 skid steer loader driveline system components: a 203.1 cu.in (3.3L) Cat C3.3B DIT 4-cylinder turbocharged diesel engine with a rated power of 72.9 hp (54.4 kW), and 2-speed hydro transmission. The hydraulic system has a pump with a rated capacity of 23 gal/min (86 l/min) or 32 gal/min (121 l/min). The system relief pressure is 3335 psi (230 bar) or 4060 psi (280 bar). The Cat 262D3 is equipped with 100HS continuous roller chains and 12x16.5 tires. The skid steer loader has a max lift height of 124.9" (3170 mm) to hinge pin and dump height of 93.7" (2380 mm). The rated operating capacity is 2700 lbs (1255 kg), and tipping load is 5400 lbs (2450 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air trapped in fuel system - Bleed air.
Clogged fuel filter - Change filter element.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Excessive valve clearance - Have it adjusted.
Fuel injection pump failure - Repair or replace injection pump.

Engine starts and stalls suddenly
Air filter is dirty - Service or replace the air filter.
Dirty fuel filter - Replace the filter element.
Fuel injection pump is leaking - Repair any leaks.
Dirty or defective injectors - Clean or replace fuel injectors.
Fuel injection pump is not operating properly - Repair or install a new fuel pump.

Engine stalls during operation
Engine is cold - Warm up the engine as required.
Dirty fuel filter - Clean or change the filter.
Air in the fuel pipes - Bleed the fuel pipes.
Faulty or dirty injection nozzles - Replace injection nozzles.
Wrong setting of fuel injection pump timing - Adjust according to specifications.

Engine stalls when idle
Low idle speed set incorrectly - Adjust low idling as recommended.
Fuel injection pump failure - Rebuild or install a new injection pump.
Fuel injectors are faulty or clogged - Clean fuel injectors or change it.
The valve clearance is not adjusted - Have it adjusted.

Engine power is too low
Air cleaner is clogged - Service or replace air cleaner.
Faulty fuel injection nozzles - Check and replace nozzles if required.
Improper fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Incorrect valve clearance - Check and adjust.
Incorrect low idle setting - Need to adjust idle speed.
Fuel lines or hoses clogging - Clean fuel system lines and hoses.
Cylinder head gasket is blown - Change cylinder head gasket.
Defective or worn piston rings - Install new piston rings.

Engine overheats
Engine has a lack of coolant - Fill radiator to proper level and check components for faults.
Not enough engine oil - Check and refill engine oil.
Clogged radiator core or damaged radiator cap - Change cap or clean radiator.
Fan belt is broken or worn - Fan belt must be replaced.
Engine overload - Load reducing is recommended.

Low oil pressure
Engine oil insufficient - Fill the crankcase with oil.
Oil filter element clogged - Service or replace engine oil filter.
Wrong oil viscosity - Use proper viscosity oil.
Crankshaft bearing oil clearance is incorrect - Bearing replacement required.
Oil pump malfunction - Replace as required.

Engine knocking or noise
Insufficient engine oil - Need to add engine oil.
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Wrong setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Low idle speed adjustment is incorrect - Correct low idle settings.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Connecting rod is defective or misaligned - Connecting rod needs to be aligned or changed.
Pistons are worn or scored - Install new pistons.

Drive System Troubleshooting

Drive system does not work in either direction
Low hydraulic fluid level - Add fluid as required.
Worn drive chain - Check drive chain and change defective parts.
Input drive shaft is damaged - Replace drive shaft.
Defective relief valve - Change or repair defective relief valve.
Hydraulic filter or suction line is clogged - Service suction line or replace hydraulic filter.
Foot or hand controls are faulty - Check and repair as required.
Drive pump or motor malfunction - Check and repair if required.

Power is too low
Hydraulic oil filter is dirty - Check, clean, or change as necessary.
Relief valve is defective or opened - Change or close relief valve.
Faulty or worn transmission components - Check and change faulty components.
Input drive shaft failure - Service or change faulty drive shaft.
Hydraulic system is leaking air - Bleed air from system.

Drive system overheating
Low hydraulic oil level - Need to add oil.
Clogged hydraulic fluid filter - Change hydraulic filter.
Worn or damaged relief valve - Relief valve need to be replaced or repair.
Defective drive pump or hydraulic motor - Change or repair faulty component.
Oil cooler is clogged - Cooling fins need to be cleaned.
Overloaded drive system - Load needs to be reduced.

Drive system is excessively noisy
Oil viscosity is too heavy - Use the specified type of oil.
Air in hydraulic system - Need to bleed air.
Worn hydraulic motor or drive pump - Inspect and replace as necessary.
Worn or defective mechanical parts of drive system - Check the components for worn or defect and replace if necessary.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Adjust it correctly.
Main relief valve improper adjustment or failure - Adjust relief valve or change if required.
Hydraulic fluid contamination - Change hydraulic fluid.
Lack of hydraulic fluid - Fill the hydraulic system with oil.
Hydraulic pump is faulty - Repair or change pump if required.

Boom fails to lift or drop
Lift controls are defective - Inspect and repair if necessary.
Hydraulic pump failure - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Repair or replace hydraulic valve.
Hydraulic cylinder is faulty - Change or repair lift cylinder.
Low hydraulic fluid level - Fill up the hydraulic fluid.

Bucket does not function
Damaged bucket controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Repair or change pump if required.
Defective hydraulic control valve - Repair or change the valve.
Faulty hydraulic bucket cylinder - Repair or change cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Boom or bucket functions slowly
Faulty hydraulic oil pump - Test pump flow rate and replace pump if required.
Hydraulic cylinder leaking - Cylinder seals need to be replaced.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Worn or unadjusted hydraulic control valve - Repair or adjust properly.
Hydraulic pressure has dropped - Adjust pressure as required.

Lift arm or bucket is jerky
Air in the hydraulic system - Bleed hydraulic system.
Clogged hydraulic oil filter element - Change or clean oil filter.
Hydraulic fluid contamination - Hydraulic fluid change required.
Cylinder tube or rod is scored - Change worn component.

Hydraulic pump is excessively noisy
Low oil level or hydraulic leaks - Add hydraulic oil or correct system leaks.
Dirty hydraulic filter - Clean or change the filter.
Suction line is clogged - Suction line needs to be cleaned.
Air enters the pump - Need to bleed air.
Damaged pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery won’t charge
Corroded or loose wire connections - Clean or tighten wiring connections.
Defective battery terminal clamps - Terminal clamps should be changed.
Battery faulty cell - Replace the battery.
Belt is defective or loose - Adjust belt tension or install a new belt.

Starter turns slowly
Low battery output voltage - Battery is drained, recharge it.
Battery will not hold charge - Service battery or replace it.
Disconnected cables or faulty battery terminals - Check wire connections and change or service terminals.

Starter will not work
Battery is drained or worn - Need to charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery power - Recharge the battery.
Starter motor is defective - Replace or repair starter.