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Caterpillar 262D Troubleshooting

The Cat 262D skid steer loader driveline system components: 203.1 cu.in (3.3L) Caterpillar C3.3B DIT 4-cylinder turbocharged diesel engine with a rated power of 72.9 hp (54.4 kW), and 1-speed or 2-speed hydrostatic 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 Caterpillar 262D is equipped with a vertical-lift loader boom, 100HS drive chains, and 12.00x16.5 standard tires. The skid steer loader has a maximum 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 (1225 kg), and tipping load is 5400 lbs (2450 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start
Air in the fuel system - Air bleeding.
Fuel filter plugged - Clean or replace the filter.
Fuel injection nozzles are damaged or dirty - Service or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is not adjusted - Adjustment procedure required.
Fuel injection pump damage - Replace injection pump or repair it.

Engine starts but then stalls
Plugged air filter - Install new air filter element.
Clogged fuel filter - Replace the filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Defective or clogged fuel injectors - Clean fuel injectors or change it.
Fuel injection pump failure - Replace injection pump or repair it.

Engine stops unexpectedly during operation
Low coolant temperature - Warm up engine as required.
Clogged fuel filter - Clean the filter or install new filter element.
Air in the fuel system - Air bleeding.
Fuel injection nozzles are dirty or defective - Inspect nozzles and replace if necessary.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.

Engine stops at idle
Low idle speed adjustment is incorrect - Correct low idle adjustment.
Fuel injection pump is broken - Replacement or repair required.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Valve clearance is wrong - Need to adjust valve clearance.

Diesel engine is losing power
Air filter is clogged - Replace or clean air filter element.
Fuel injection nozzles are damaged - Check injection nozzles and replace if required.
Improper fuel injection pressure - Correct the pressure settings.
Valve out of adjustment - Correct valve clearance.
Improperly adjusted low idle speed - Correct the settings.
Dirt in the fuel lines or hoses - Fuel hoses and lines must be clean.
Damaged cylinder-head gasket - Gasket should be replaced.
Piston rings are damaged or leaking - Change piston rings.

Engine overheats
Low engine coolant - Add coolant and check the components of cooling system.
Engine oil level low - Checking oil level and add if necessary.
Clogged radiator core or damaged radiator cap - Install new cap or clean radiator.
Loose or damaged fan belt - Change the fan belt.
Engine overloaded - Reduce engine load.

Oil pressure too low
Low oil level - Check and refill the oil.
Dirty oil filter - Change or clean engine oil filter element.
Incorrect oil viscosity - Fill up with the correct oil viscosity.
Incorrect oil clearance in main bearing - Install new bearings.
Oil pump is worn or damaged - Install a new pump.

Engine knocking or noise
Insufficient engine oil - Add oil to the engine crankcase.
Engine is not preheated - Warm up the engine.
Timing of fuel injection pump is incorrect - Adjust as recommended.
Incorrect low idle speed adjustment - Test and adjust.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Connecting rod is misaligned or defective - Alignment procedure or replacement is required.
Piston wear or scoring - Install new pistons.

Drive System Troubleshooting

Machine will not move in either direction or one direction
Hydraulic oil level is low - Checking hydraulic oil level and add if necessary.
Drive chain is worn - Check drive chain and change faulty parts.
Relief valve is damaged or worn - Change or repair relief valve.
Plugged suction line or hydraulic filter - Service suction line or replace hydraulic filter.
Faulty hand or foot controls - Change or repair.
Drive pump or motor malfunction - Inspect and replace as necessary.

Low power
Plugged hydraulic oil filter - Replace or service hydraulic filter.
Open or faulty relief valve - Change or close relief valve.
Transmission components are damaged or faulty - Inspect and change faulty parts.
Worn input drive shaft - Replace drive shaft.
Air trapped in hydraulic system - Bleed hydraulic system.

Drive system overheats
Low hydraulic oil level - Check and refill the hydraulic oil.
Dirty hydraulic fluid filter - Replace hydraulic filter.
Relief valve is damaged or worn - Repair or change.
Damaged drive pump or hydraulic motor - Inspect and replace as necessary.
Oil cooler is clogged - Cooling fins should be cleaned.
Drive system is overloaded - Reduce the load.

Drive system makes excessive noise
Incorrect oil viscosity - Use oil of proper viscosity.
Air trapped in hydraulic system - Need to bleed air.
Drive pump or hydraulic motor malfunction - Inspect and replace as necessary.
Mechanical components of drive system are worn or damaged - Check the parts for defect or damage and change if required.

Hydraulics Troubleshooting

Hydraulic system overheating
Incorrect hydraulic pressure setting - Adjust pressure correctly.
Faulty or improperly adjusted main relief valve - Set up or change the relief valve.
Hydraulic oil contamination - Hydraulic oil change required.
Not enough hydraulic oil in the system - Add oil to the hydraulic system.
Hydraulic pump is defective - Install new pump or repair it.

Boom fails to lift or drop
Lift controls are damaged - Inspect and repair if necessary.
Hydraulic pump failure - Change or repair hydraulic pump if required.
Damaged hydraulic control valve - Replace or repair the valve.
Hydraulic cylinder is broken - Replace or repair boom cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket does not tilt
Bucket tilt controls malfunction - Change or repair.
Hydraulic pump malfunction - Replace or repair pump if necessary.
Hydraulic control valve failure - Repair or replace hydraulic valve.
Bucket cylinder is faulty - Replace or repair cylinder.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.

Boom or bucket moves slowly
Defective hydraulic pump - Check pump flow and change pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Faulty or incorrect setting hydraulic control valve - Set properly or repair.
Hydraulic pressure is low - Adjust pressure correctly.

Jerky operation of the bucket or boom
Air in hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil filter - Change or clean oil filter.
Dirty hydraulic fluid - Fill up with fresh hydraulic fluid.
Cylinder tube or rod scoring - Replace damaged component.

Excessive hydraulic pump noise
Hydraulic leakage or lack of oil - Top up hydraulic oil or remedy leakage in system.
Plugged hydraulic filter - Service or change hydraulic filter.
Suction line is dirty - Need to service the suction line.
Air trapped in hydraulic pump - Bleed air.
Damaged pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery won’t charge
Loose or corroded electrical wiring connections - Tighten or service connections.
Battery terminal connectors are faulty - Replace terminal connectors.
Battery is worn - Replace the battery.
Loose or defective belt - Belt needs to be adjusted or replaced.

Starter cranks slowly
Battery power is low - Low battery charging, charge as required.
Battery will not hold charge - Battery needs to be serviced or replaced.
Terminals are faulty or battery cables are disconnected - Check cables and clean or change terminals.

Starter motor won't turn
Battery is discharged or defective - Need to charge or replace the battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery capacity - Charge the battery.
Starter motor is defective - Repair or replace starter.