Caterpillar 246D3 Skid Steer Troubleshooting

The Cat 246D3 skid steer loader is powered by 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) at 2500 rpm. The Cat 246D3 is equipped with a two-speed hydrostatic transmission, radial-lift loader boom, 100HS continuous roller chains, and 12x16.5 tires. The hydraulic system has a high flow XPS pump with flow rate of 32 gpm (121 lpm). The high flow XPS hydraulic pressure is 4060 psi (280 bar). The skid steer loader has a rated operating capacity of 2200 lbs (1000 kg) and tipping load of 4400 lbs (2000 kg). The lift height is 124.2" (3155 mm) to hinge pin, and dump height is 97.1" (2465 mm).

Engine Troubleshooting

Engine starts hard or won't start

There is air in the fuel system - Bleed the system.
Fuel filter element clogging - Service the filter.
Fuel injection nozzles are damaged - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Adjust valve clearance.
Fuel injection pump malfunction - Install a new pump or rebuild.

Engine starts and immediately shuts off

Plugged air filter - Change or service air filter element.
Fuel filter element clogging - Service or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Damaged fuel injection pump - Replace or repair injection pump.

Engine stalls while running

Engine is not preheated - Warm up the engine.
Fuel filter element clogging - Change filter element.
Air in fuel system - Bleed fuel system.
Clogged or burnt injection nozzle - Inspect nozzles and replace if necessary.
Fuel injection pump timing is wrong - Check the fuel injection pump timing adjustment.

Engine stalling at idle

Improperly adjusted low idle speed - Correct low idle adjustment.
Fuel injection pump is not operating properly - Repair or install new pump.
Defective fuel injectors - Clean or replace fuel injectors.
Improper valve clearance - Need to adjust valve clearance.

Engine power is insufficient

Air filter is dirty - Clean or change.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Incorrect fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Improper valve clearance - Adjustment procedure required.
Incorrectly adjusted low idle speed - Correct low idle adjustment.
Dirt in the fuel lines or hoses - Service fuel hoses and lines.
Cylinder head gasket is damaged - Cylinder-head gasket replacement required.
Worn or broken piston rings - Change piston rings.

Engine is overheated

Engine has a lack of coolant - Refill to the correct level and inspect system for leaks.
Insufficient engine oil - Fill up the oil to required level.
Radiator core is dirty or radiator cap is damaged - Clean radiator or install new cap.
Loose or defective fan belt - Change the fan belt.
Engine is under excessive load - Reduce engine load.

Oil pressure is insufficient

Engine oil level low - Check and refill the oil.
Clogged oil filter element - Clean or replace engine oil filter element.
Incorrect oil viscosity - Drain crankcase and refill with correct oil.
Crankshaft bearing oil clearance is excessive - Install new bearings.
Defective oil pump - Repair or replace.

Engine knocking sound or abnormal noise

Lack of engine oil - Add oil to the engine crankcase.
Low coolant temperature - Warm up the engine.
Improper fuel injection timing - Set up as recommended.
Incorrectly set low idle speed - Adjust low idle speed.
Defective fuel injectors - Clean or replace fuel injectors.
Connecting rod misalignment or failure - Connecting rod must be aligned or replaced.
Pistons are worn or broken - Pistons need to be replaced.

Drive System Troubleshooting

Drive system won't work in one direction or either direction

Hydraulic oil level is low - Need to add oil.
Drive chain fault - Inspect drive chain and replace faulty parts.
Defective input drive shaft - Rebuild or change.
Relief valve is stuck - Repair or replace relief valve.
Plugged suction line or hydraulic filter - Service suction line or change hydraulic filter.
Defective hand or foot controls - Repair or change.
Damaged drive pump or motor - Repair or change faulty component.

Loss of power

Clogged hydraulic oil filter - Replace hydraulic filter.
Relief valve is opened or defective - Close or replace relief valve.
Transmission parts are worn or defective - Check and replace faulty components.
Input drive shaft failure - Replace or service the drive shaft.
Air in hydraulic system - Need to bleed air.

Drive system is overheated

Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Hydraulic fluid filter is plugged - Check, clean, or change as necessary.
Relief valver is broken - Service or change relief valve.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Oil cooler is clogged - Clean the cooling fins.
Overloaded drive system - Reduce loading.

Drive system makes excessive noise

Improper oil viscosity - Use oil of proper viscosity.
Air in hydraulic system - Bleed air from system.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Worn or damaged mechanical components of drive system - Check the parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system is overheated

Hydraulic pressure is not correct - Correct adjustment is required.
Misadjusted or defective main relief valve - Adjust relief valve or change if required.
Hydraulic fluid is contaminated - Fill up with fresh hydraulic fluid.
Not enough hydraulic fluid in the system - Need to add fluid.
Hydraulic pump is worn - Repair or install new hydraulic pump.

Boom cannot be lowered or raised

Faulty lift controls - Change or repair.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic cylinder failure - Repair or install a new lift cylinder.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.

Bucket won't move

Bucket controls are faulty - Repair or replace.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is faulty - Repair or replace hydraulic valve.
Hydraulic bucket cylinder not working - Install a new cylinder or repair it.
Hydraulic fluid level low - Add fluid as required.

Bucket or lift arm is moving slowly

Hydraulic pump is worn - Check the pump capacity and replace pump if required.
Hydraulic cylinder oil leakage - Correct leakage by changing the seals.
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Hydraulic control valve is unadjusted or worn - Adjust properly or repair.
Hydraulic pressure loss - Set pressure correctly.

Bucket or boom is jerky

Air leaks in hydraulic system - Need to bleed air.
Hydraulic oil filter is dirty - Service or change the hydraulic filter.
Hydraulic oil is dirty - The oil must be changed.
Cylinder rod or tube is scuffed - Replace worn component.

Hydraulic pump is excessively noisy

Leaking hydraulic system or insufficient oil level - Refill hydraulic oil or repair leaks in system.
Hydraulic filter clogging - Clean or replace the filter.
Plugged suction line - Suction line needs to be cleaned.
Pump sucks air - Bleed air.
Damaged pump parts - Change or rebuild pump.

Electrical Troubleshooting

Battery is not charging

Loose or corroded wire connections - Tighten or clean electrical wiring connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Dead cell in battery - Replace the battery.
Belt is damaged or loose - Install a new belt or adjust belt tension.

Starter turns slow

Battery voltage is low - Low battery charging, charge as required.
Battery discharges quickly - Service battery or replace it.
Battery cables are disconnected or terminals are faulty - Check cables and service or change terminals.

Starter does not work

Battery is low or faulty - Recharge or replace battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery power is low - Battery is drained, recharge it.
Starter motor failure - Starter should be changed.