Caterpillar 249D3 Track Loader Troubleshooting

The Caterpillar 249D3 compact track loader driveline system components: a 134.1 cu.in (2.2L) Cat C2.2T 4-cylinder turbocharged diesel engine with a rated power of 65.8 hp (49.1 kW), and 2-speed hydro transmission. The high flow hydraulic system has a pump with a rated flow of 26 gpm (99 lpm). The system pressure is 3335 psi (230 bar). The Cat 249D3 is equipped with vertical-lift boom, axial-piston drive pumps, and 12.6 (320 mm) or 15.7" (400 mm) steel embedded rubber tracks. The loader has a max lift height of 118.2" (3 m) to hinge pin and dump height of 88.7" (2.3 m). The rated operating capacity is 1740 lbs (790 kg), and tipping load is 4970 lbs (2260 kg).

Engine Troubleshooting

Engine difficult to start or will not start

Air in the fuel lines - Bleed the fuel lines.
Clogged fuel filter - Clean or replace the filter.
Clogged or burnt injection nozzle - Check and replace nozzles if required.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is wrong - Correct valve clearance needs to be set.
Fuel injection pump is broken - Repair or replace injection pump.

Diesel starts but stalls immediately

Plugged air filter - Service or replace the air filter.
Fuel filter element clogging - Install new filter element.
Fuel injection pump has loose connections - Tighten the connections.
Defective or clogged fuel injectors - Inspect fuel injectors and change as required.
Damaged fuel injection pump - Rebuild or install a new injection pump.

Engine shuts off suddenly during operation

Engine not warmed up - Warm up the engine as required.
Fuel filter plugging - Replace filter element.
Air in the fuel system - Air bleeding.
Dirty or damaged injection nozzles - Service or change injection nozzles.
Improper fuel injection timing - Set it up as required.

Engine stalls when idle

Incorrectly set low idle speed - Adjustment required.
Defective fuel injection pump - Replace injection pump or repair it.
Clogged or defective injectors - Clean fuel injectors or change it.
The valve clearance is not adjusted - Adjust valve clearance.

Engine power loss

Air cleaner is dirty - Install new air cleaner element.
Clogged injection nozzle - Change fuel injection nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
The valve clearance is incorrect - Correct valve clearance needs to be set.
Wrong adjustment of low idle speed - Correct low idle adjustment.
Restricted fuel lines or hoses - Service fuel lines and hoses.
Blown cylinder head gasket - Cylinder-head gasket replacement required.
Worn or broken piston rings - Change piston rings.

Engine overheats

Lack of engine coolant - Add coolant and check the components of cooling system.
Engine oil level is insufficient - Add oil to the engine crankcase.
Radiator core is dirty or radiator cap is damaged - Clean radiator or change cap.
Loose or defective fan belt - Replace as required.
Diesel engine is overloaded - Reduce engine load.

Oil pressure is insufficient

Low oil level - Fill crankcase to proper oil level.
Oil filter clogged - Change or clean engine oil filter element.
Oil grade or viscosity is wrong - Use oil of correct viscosity.
Crankshaft bearing has incorrect oil clearance - Bearing replacement required.
Oil pump failure - Repair or replace.

Engine knocks or noises

Lack of engine oil - Need to add engine oil.
Engine is cold - Warm up engine as required.
Fuel injection pump timing is not adjusted - Adjust as recommended.
Incorrectly adjusted low idle speed - Adjustment required.
Dirty or defective injectors - Clean fuel injectors or change it.
Connecting rod misalignment or failure - Need to align or replace the connecting rod.
Broken or worn pistons - Pistons need to be replaced.

Drive System Troubleshooting

Drive system doesn't work in either direction

Insufficient hydraulic oil - Need to add oil.
Track mechanism is defective or jammed - Remove jamming or repair tracks.
Defective relief valve - Relief valve need to be replaced or repair.
Clogged hydraulic filter or suction line - Service suction line or replace hydraulic filter.
Hand or foot controls failure - Change or repair.
Defective drive pump or motor - Change or repair faulty component.

Machine does not move straight or moves jerky

Undercarriage tracks are jammed or defective - Repair or fix jamming.
Sagging or worn tracks - Correct track sag with tensioning or repair tracks.
Track frame is clogged with debris, dirt, or foreign objects - Remove debris or foreign objects and clean track frame.

Loss of power

Hydraulic oil filter is dirty - Check, clean, or replace as required.
Relief valve is open or defective - Change or close relief valve.
Faulty or damaged transmission components - Check and replace faulty components.
Input drive shaft is defective - Repair or replace drive shaft.
Air trapped in hydraulic system - Need to bleed air.

Drive system overheating

Hydraulic oil is insufficient - Need to add oil.
Plugged hydraulic fluid filter - Change hydraulic filter.
Defective or worn relief valve - Change or repair defective relief valve.
Hydraulic motor or drive pump failure - Change or repair faulty component.
Plugged hydraulic oil cooler - Cooling fins should be cleaned.
Transmission overloading - Load needs to be reduced.

Drive system is excessively noisy

Improper oil viscosity - Use oil of correct viscosity.
Air in the hydraulic system - Bleed hydraulic system.
Hydraulic motor or drive pump is defective - Replace or repair faulty component.
Worn or damaged mechanical parts of drive system - Inspect the components for worn or defect and repair as required.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure is incorrect - Adjust pressure as required.
Main relief valve improper adjustment or failure - Replace or set up the relief valve.
Hydraulic oil contamination - Change hydraulic oil.
Lack of hydraulic oil - Fill up the hydraulic oil.
Hydraulic pump is worn - Install new pump or repair it.

Boom won't lower or raise

Lift controls malfunction - Repair or change.
Hydraulic pump is broken - Replace or repair pump if necessary.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Hydraulic cylinder is faulty - Repair or change hydraulic cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket is not working

Bucket tilt controls malfunction - Repair or replace.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Hydraulic control valve failure - Replace or repair the valve.
Broken bucket cylinder - Install a new cylinder or repair it.
Low hydraulic oil level - Need to add oil.

Bucket or lift arm moves slowly

Faulty hydraulic oil pump - Test the pump flow rate and install new pump if required.
Leaking hydraulic cylinder - Install new cylinder seals.
Hydraulic fluid is insufficient - Add fluid as required.
Damaged or incorrect adjusted hydraulic control valve - Repair or set properly.
Hydraulic pressure is low - Correct adjustment is required.

Bucket or boom movements are jerky

Air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element is clogged - Clean or install new filter.
Contaminated hydraulic fluid - The fluid must be changed.
Scored cylinder tube or rod - Change defective component.

Hydraulic pump is noisy

Hydraulic leaks or low oil level - Correct hydraulic leaks or top up oil as needed.
Dirty hydraulic filter - Clean or install new filter.
Dirty suction line - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Remove air from hydraulics.
Pump components are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery does not charge

Loose or corroded wire connections - Clean or tighten wiring connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Faulty cell in battery - Install a new battery.
Belt is defective or loose - Adjust belt tension or change the belt.

Starter cranks slow

Low battery voltage - Recharge the battery.
Battery does not hold charge - Service battery or replace it.
Bad terminals or disconnected battery cables - Check cable connections and replace or service terminals.

Starter will not crank

Battery is discharged or defective - Recharge or replace battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery output voltage - Battery needs to be recharged.
Damaged starter motor - Starter should be replaced.