Caterpillar 232B Skid Steer Troubleshooting

The Cat 232B skid steer loader is powered by 134.1 cu.in (2.2L) Caterpillar 3024C four-cylinder direct injection liquid cooled diesel engine with a rated power of 49 hp (37 kW) at 2600 rpm. The Cat 232B is equipped with a single-speed hydrostatic transmission, wet multi disc brakes, 80HS roller chains, 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 3100 psi (214 bar). The skid steer loader has a rated operating capacity of 1750 lbs (793 kg) and tipping load of 3500 lbs (1588 kg). The lift height is 118.7 inches (3015 mm) to hinge pin, and dump height is 88.3 inches (2245 mm).

Engine Troubleshooting

Engine difficult to start or will not start

There is air in the fuel system - Bleed the system.
Dirty fuel filter - Service or replace the filter.
Clogged or burnt injection nozzle - If necessary, replace with a new nozzle.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Adjustment procedure required.
Fuel injection pump is defective - Change or repair the pump.

Diesel starts and stalls immediately

Plugged air cleaner - Clean or change cleaner.
Fuel filter plugged - Change filter element.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Inspect fuel injectors and change as required.
Fuel injection pump failure - Rebuild or replace pump.

Engine stops unexpectedly during operation

Coolant temperature is low - Warm up engine as required.
Dirty fuel filter - Replace filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Faulty fuel injection nozzles - If necessary, replace with a new nozzle.
Improper setting of fuel injection pump timing - Check the fuel injection pump timing adjustment.

Engine stalls while idling

Improperly adjusted low idle speed - Adjust low idling as recommended.
Fuel injection pump is damaged - Rebuild or change fuel pump.
Fuel injectors are faulty or clogged - Replace or clean fuel injectors.
Valve out of adjustment - Adjust to proper valve clearance.

Engine power loss

Clogged air filter - Service or replace the air filter.
Defective or clogged injection nozzle - Check and replace nozzles if required.
Fuel injection pressure is wrong - Correct the pressure settings.
Valve clearance is not correct - Check and adjust as required.
Low idle speed set incorrectly - Adjust low idling as recommended.
Fuel lines or hoses are dirty - Clean fuel system lines and hoses.
Cylinder head gasket is defective - Replace the gasket as required.
Leaking or defective piston rings - Piston rings need to be replaced.

Engine overheated

Coolant level is low - The cooling system needs to be refilled and checked for faults.
Engine oil level is low - Checking oil level and add if necessary.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or replace cap.
Broken or loose fan belt - Replace the fan belt.
Diesel engine overloaded - Reduce engine load.

Oil pressure is low

Oil level is insufficient - Checking oil level and add if necessary.
Plugged engine oil filter - Replace or clean engine oil filter element.
Different type of engine oil - Fill up with the proper oil viscosity.
Crankshaft bearing has incorrect oil clearance - Replace bearings.
Worn oil pump - Install a new pump.

Engine knocks or noises

Engine oil insufficient - Checking oil level and add if necessary.
Engine is cold - Warm up engine as required.
Incorrect adjustment of fuel injection pump timing - Set it up as required.
Incorrectly set low idle speed - Correct low idle settings.
Clogged or defective injectors - Clean or replace fuel injectors.
Misaligned or faulty connecting rod - Connecting rod needs to be replaced or aligned.
Worn or broken pistons - Install new pistons.

Drive System Troubleshooting

Drive system won't operate in either direction

Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Drive chain is worn - Check drive chain and change faulty parts.
Worn input drive shaft - Replace or service the drive shaft.
Worn or defective relief valve - Service or change relief valve.
Dirty hydraulic filter or suction line - Replace hydraulic filter or clean suction line.
Hand or foot controls malfunction - Check and repair as required.
Drive motor or pump is worn - Inspect and change as required.

Lack of power

Hydraulic oil filter is plugged - Check, clean, or replace as required.
Worn or open relief valve - Replace or close relief valve.
Faulty or damaged transmission components - Inspect and replace defective parts.
Input drive shaft is damaged - Rebuild or change the shaft.
There is air in the hydraulic system - Need to bleed air.

Overheated drive system

Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Hydraulic fluid filter is clogged - Replace or service hydraulic filter.
Relief valve is not working correctly - Change or repair relief valve.
Damaged drive pump or hydraulic motor - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Cooling fins should be cleaned.
Overloaded drive system - Load needs to be reduced.

Excessive noise

Wrong oil viscosity - Use oil of proper viscosity.
Air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic motor or drive pump is defective - Inspect and change as required.
Mechanical parts of drive system are defective or worn - Inspect drive system and replace faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheated

Hydraulic pressure is not adjusted correctly - Set pressure correctly.
Main relief valve is faulty or misadjusted - Adjust relief valve or change if required.
Dirty hydraulic oil - Hydraulic oil change required.
Lack of hydraulic oil - Check oil level and add hydraulic oil as required.
Worn hydraulic oil pump - Replace or repair pump if necessary.

Boom fails to lift or drop

Lift controls malfunction - Check and repair as required.
Defective hydraulic pump - Replace or repair pump if necessary.
Damaged hydraulic control valve - Change or repair hydraulic valve.
Broken hydraulic cylinder - Replace or repair boom cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Bucket does not tilt

Faulty bucket tilt controls - Inspect and repair if necessary.
Hydraulic pump not working - Replace or repair pump if necessary.
Defective hydraulic control valve - Install a new valve or repair it.
Defective bucket cylinder - Change or repair cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Bucket or lift arm moves slowly

Hydraulic pump is worn - Test pump performance and replace pump if necessary.
Oil leaks from hydraulic cylinder - Cylinder seals need to be replaced.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is not set properly or defective - Adjust properly or repair.
Low hydraulic pressure - Adjust it correctly.

Bucket or boom is moving jerkily

Air trapped in hydraulic system - Need to bleed air.
Hydraulic oil filter clogging - Service or replace the hydraulic filter.
Dirty hydraulic oil - Hydraulic oil change required.
Scored cylinder tube or rod - Change failed component.

Hydraulic pump is excessively noisy

Hydraulic leakage or low oil level - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is clogged - Service or replace hydraulic filter.
Plugged suction line - Suction line must be serviced.
Pump sucks air - Air bleeding is required.
Pump parts are faulty - Replace or rebuild the pump.

Electrical Troubleshooting

Battery is not charging

Corroded or loose wire connections - Clean or tighten connections.
Faulty electrical terminal connectors - Terminal connectors should be replaced.
Battery faulty cell - Battery change required.
Damaged or loose belt - Adjust belt tension or change the belt.

Starter motor cranks slow

Battery voltage is low - Battery needs to be recharged.
Battery is not holding charge - Service charging system or install new battery.
Disconnected cables or faulty battery terminals - Connect wiring correctly or install new terminals.

Starter is not cranking

Battery is drained or worn - Change or recharge battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery power - Recharge the battery.
Starter motor is faulty - Change or repair starter.