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Caterpillar 272D Troubleshooting

The Cat 272D skid steer loader is powered by 232 cu.in (3.8L) Caterpillar C3.8 DIT 4-cylinder turbocharged liquid cooled diesel engine with a rated power of 95 hp (71 kW) at 2400 rpm. The Caterpillar 272D is equipped with a single-speed or two-speed hydrostatic transmission, vertical-lift loader boom, 100HS drive chains, and 12.00x16.5 standard tires. The hydraulic system has a pump with fluid flow rate of 23 gpm (86.4 lpm) or 32 gpm (120 lpm). The skid steer loader has a rated operating capacity of 3200 lbs (1450 kg) and tipping load of 6400 lbs (2900 kg). The boom breakout force is 7405 lbs (3360 kg), and bucket breakout force is 6100 lbs (2765 kg).

Engine Troubleshooting

Engine hard to start or will not start
Air trapped in fuel system - Bleed air.
Dirty fuel filter - Replace the filter element.
Faulty or dirty injection nozzles - Inspect nozzles and replace if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Incorrect valve clearance - Adjust valve clearance.
Fuel injection pump is defective - Rebuild or change fuel pump.

Engine starts but stalls suddenly
Air filter is dirty - Clean or change.
Clogged fuel filter - Service or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Clean or replace fuel injectors.
Fuel injection pump is faulty - Change pump or rebuild it.

Engine stalls during operation
Engine is cold - Normalize the temperature by warming up the engine.
Dirty fuel filter - Install new filter element.
Air in the fuel lines - Bleed the fuel lines.
Damaged or dirty injection nozzles - Test injection nozzles and change if necessary.
Improper setting of fuel injection pump timing - Adjust as recommended.

Engine stalls while idling
Low idle speed setting is incorrect - Adjustment required.
Fuel injection pump damage - Change or repair the pump.
Fuel injector fault - Inspect fuel injectors and change as required.
Improper valve clearance - Correct valve clearance.

Engine power is insufficient
Dirty air filter - Clean or replace element.
Faulty or dirty injection nozzles - Inspect nozzles and replace if necessary.
Fuel injection pressure is wrong - Correct the pressure settings.
Valve clearance is not correct - Correct valve clearance needs to be set.
Low idle speed set incorrectly - Adjust the low idle speed.
Restricted fuel lines or hoses - Clean fuel hoses and lines.
Cylinder head gasket is defective - Cylinder-head gasket replacement required.
Piston rings are damaged or leaking - Replace the piston rings as required.

Engine overheated
Lack of engine coolant - Fill the cooling system and check components for leaks or other faults.
Engine oil level is insufficient - Check and refill engine oil.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or change cap.
Excessive wear of the fan belt - Belt change is required.
Engine overloaded - Load reducing required.

Oil pressure is low
Oil level is insufficient - Add oil to the engine crankcase.
Oil filter clogged - Change or service engine oil filter.
Incorrect oil viscosity - Drain crankcase and refill with correct oil.
Crankshaft bearing oil clearance is excessive - Replace bearings.
Oil pump is damaged - Inspect and change as required.

Abnormal engine noise or knocking
Low engine oil level - Checking oil level and add if necessary.
Engine is cold - Warm up to required temperature.
Fuel injection pump timing is wrong - Adjust fuel injection pump as required.
Incorrect low idle setting - Adjustment required.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Connecting rod misalignment or failure - Align or replace connecting rod.
Pistons are scored or worn - Replace the pistons as required.

Drive System Troubleshooting

Drive system does not work in either direction
Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Faulty drive chain - Check drive chain and change faulty components.
Relief valve is damaged or worn - Change or repair defective relief valve.
Plugged suction line or hydraulic filter - Change hydraulic filter or service suction line.
Foot or hand controls are faulty - Change or repair.
Worn drive motor or pump - Change or repair faulty component.

Reduced power
Hydraulic oil filter is dirty - Check, clean, or replace as required.
Relief valve is damaged or open - Close or change relief valve.
Faulty or worn transmission components - Check and change defective components.
Input drive shaft malfunction - Replace drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Drive system is overheated
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Hydraulic fluid filter is clogged - Replace or clean hydraulic filter.
Relief valve defective or worn - Repair or install a new relief valve.
Hydraulic motor or drive pump is worn - Inspect and replace as necessary.
Hydraulic oil cooler is dirty - Cooling fins should be cleaned.
Drive system overloaded continuously - Reduce loading.

Drive system is excessively noisy
Incorrect oil viscosity - Use the specified type of oil.
There is air in the hydraulic system - Bleed air from system.
Worn hydraulic motor or drive pump - Inspect and change as required.
Worn or damaged mechanical parts of drive system - Inspect drive system and replace faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Correct adjustment is required.
Main relief valve is defective or unadjusted - Replace or set up the relief valve.
Dirty hydraulic oil - Change hydraulic oil.
Hydraulic oil level is insufficient - Add oil to the hydraulic system.
Defective hydraulic pump - Repair or install new hydraulic pump.

Boom can't lift or drop
Lift controls malfunction - Change or repair.
Damaged hydraulic oil pump - Install new pump or repair it.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Hydraulic cylinder is broken - Change or repair lift cylinder.
Hydraulic oil level low - Need to add oil.

Bucket is not working
Bucket tilt controls are damaged - Repair or replace.
Hydraulic pump is broken - Repair or install new hydraulic pump.
Defective hydraulic control valve - Repair or change the valve.
Broken bucket cylinder - Change or repair cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket or lift arm moves slowly
Defective hydraulic pump - Check pump flow and install new pump if necessary.
Oil leaks from hydraulic cylinder - Cylinder seals need to be replaced.
Hydraulic oil level low - Check and refill the hydraulic oil.
Hydraulic control valve is defective or set improper - Repair or set properly.
Low hydraulic pressure - Correct setting is required.

Lift arm or bucket is moving jerkily
Air in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is dirty - Clean or replace the filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Cylinder tube or rod scoring - Replace defective component.

Hydraulic pump is excessively noisy
Hydraulic leakage or lack of oil - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter is dirty - Service or replace hydraulic filter.
Suction line is dirty - Suction line needs to be cleaned.
Air enters the pump - Need to bleed air.
Pump parts are worn out - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery will not charge
Corroded or loose cable connections - Clean or tighten wiring connections.
Defective battery terminal connectors - Install new terminal connectors.
Battery dead cell - Battery change required.
Belt is damaged or loose - Need to adjust belt tension or replace belt.

Starter turns slow
Battery voltage is low - Battery is drained, recharge it.
Battery does not hold charge - Service or replace the battery.
Disconnected wiring or bad battery terminals - Connect wiring properly or install new terminals.

Starter doesn't crank
Battery is low or faulty - Replace or charge as required.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery output voltage - Charge the battery.
Starter motor failing - Starter needs to be replaced.