Caterpillar 259B3 Track Loader Troubleshooting

The Caterpillar 259B3 compact track loader driveline system components: a 207.5 cu.in (3.4L) Cat C3.4 DIT 4-cylinder turbo diesel engine with a rated power of 71 hp (53 kW), and 2-speed hydro transmission. The hydraulic system has a pump with a rated flow of 22 gpm (83 lpm) or 31 gpm (117 lpm). The system pressure is 3335 psi (230 bar). The Cat 259B3 is equipped with a vertical-lift loader boom, fully suspension undercarriage, and 12.6" (320 mm) or 15.7" (400 mm) rubber tracks. The loader has a max lift height of 120" (3.05 m) to hinge pin and dump height of 88.3" (2.25 m). The rated operating capacity is 2065 lbs (937 kg), and tipping load is 5900 lbs (2676 kg).

Engine Troubleshooting

Engine hard to start or won't start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is dirty - Service or replace the filter.
Burnt or clogged injection nozzle - Clean or replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Adjust to proper valve clearance.
Damaged fuel injection pump - Rebuild or change fuel pump.

Diesel starts but stalls suddenly

Air cleaner is clogged - Clean or change.
Fuel filter element is dirty - Replace the filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Defective fuel injection pump - Rebuild or install a new injection pump.

Engine stalls while running

Engine is cold - Normalize the temperature by warming up the engine.
Dirty fuel filter - Clean the filter or install new filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are faulty or clogged - Test injection nozzles and change if necessary.
Timing of fuel injection pump is incorrect - Set it up as required.

Engine stops when idling

Wrong adjustment of low idle speed - Correct low idle settings.
Fuel injection pump is damaged - Repair or install a new fuel pump.
Dirty or defective injectors - Clean fuel injectors or change it.
Excessive valve clearance - Adjust to proper valve clearance.

Low engine power

Clogged air cleaner - Clean or change cleaner.
Clogged or defective injection nozzles - Check and replace nozzles if required.
Uneven fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Improper valve clearance - Have it adjusted.
Low idle speed setting is not correct - Adjust low idling as recommended.
Clogged fuel lines or hoses - Clean fuel system hoses and lines.
Defective cylinder head gasket - Change cylinder head gasket.
Leaking or damaged piston rings - Install new piston rings.

Engine overheated

Lack of coolant in cooling system - Refill to the correct level and inspect system for leaks.
Engine oil insufficient - Check oil level and add oil as required.
Dirty radiator fins or faulty radiator cap - Clean radiator or replace cap.
Excessive wear of the fan belt - Replace as required.
Diesel engine overloaded - Reduce load on the engine.

Oil pressure too low

Low oil level - Fill the crankcase with oil.
Clogged oil filter - Replace or clean engine oil filter element.
Oil grade or viscosity is incorrect - Fill up with the correct oil viscosity.
Excessive oil clearance of crankshaft bearing - Install new bearings.
Oil pump is defective - Repair or change.

Abnormal engine noise or knocking

Engine oil insufficient - Check and refill engine oil.
Engine is not preheated - Warm up engine as required.
Improper fuel injection timing - Adjust the pump as required.
Incorrectly set low idle speed - Adjustment required.
Fuel injectors are dirty or defective - Replace fuel injectors.
Misaligned or defective connecting rod - Connecting rod must be aligned or replaced.
Pistons are worn or scored - Replace the pistons as required.

Drive System Troubleshooting

Machine is not moving forward or backward

Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Defective or blocked track mechanism - Correct blockage or repair tracks.
Defective or worn relief valve - Change or repair defective relief valve.
Clogged hydraulic filter or suction line - Check, clean, or replace if required.
Hand or foot controls failure - Repair or replace.
Worn drive motor or pump - Inspect and change as required.

Machine is not driving straight or driving is jerky

Damaged or jammed track mechanism - Remedy jamming or repair tracks.
Tracks are worn or loose - Adjust track tension or replace tracks.
Track frame is clogged with debris, dirt, or foreign objects - Clean undercarriage track frame, remove foreign objects and debris.

Lack of power

Hydraulic oil filter is clogged - Check, clean, or change as necessary.
Worn or open relief valve - Close or change relief valve.
Transmission components are worn or defective - Inspect and change faulty parts.
Input drive shaft failure - Replace drive shaft.
Air trapped in hydraulic system - Bleed air from system.

Overheated drive system

Insufficient hydraulic fluid - Fill up the hydraulic fluid.
Clogged hydraulic fluid filter - Replace or clean hydraulic filter.
Relief valve is damaged or worn - Repair or change.
Damaged drive pump or hydraulic motor - Check and repair if required.
Clogged hydraulic oil cooler - Clean the cooling fins.
Drive system overloaded continuously - Reduce loading.

Excessive noise

Oil viscosity is wrong - Use correct oil viscosity.
Air in hydraulic system - Bleed air from hydraulic system.
Hydraulic motor or drive pump is defective - Replace or repair faulty component.
Mechanical parts of drive system are damaged or worn - Inspect the parts for defect or damage and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheating

Incorrect hydraulic pressure setting - Adjust pressure as required.
Main relief valve malfunction or improper adjustment - Adjust or change relief valve.
Contaminated hydraulic fluid - Change hydraulic fluid.
Hydraulic fluid level is low - Add fluid to the hydraulic system.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Boom won't lower or raise

Defective lift controls - Repair or replace.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve is defective - Repair or change the valve.
Faulty hydraulic cylinder - Repair or change hydraulic cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Bucket is not working

Damaged bucket controls - Repair or replace.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve malfunction - Change or repair hydraulic valve.
Faulty hydraulic bucket cylinder - Change or repair cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Bucket or lift arm is working slowly

Hydraulic pump is defective - Check pump flow and install new pump if necessary.
Hydraulic cylinder leaking - Install new cylinder seals.
Insufficient hydraulic fluid - Add fluid as required.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust properly.
Hydraulic system loosing pressure - Adjust it correctly.

Bucket or boom is jerky

There is air in the hydraulic system - Air bleeding is required.
Clogged hydraulic oil filter element - Clean or replace the filter.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Cylinder tube or rod scoring - Change damaged component.

Hydraulic pump is excessively noisy

Lack of oil or hydraulic leakage - Repair hydraulic leaks or add oil as required.
Hydraulic filter is clogged - Service or replace hydraulic filter.
Suction line is clogged - Clean suction line as required.
Pump sucks air - Air bleeding is required.
Worn pump parts - Change or rebuild pump.

Electrical Troubleshooting

Battery does not charge

Wiring connections are corroded or loose - Tighten or clean electrical wiring connections.
Battery terminal connectors are defective - Change terminal connectors.
Battery failing - Battery change required.
Defective or loose belt - Need to adjust belt tension or replace belt.

Starter turns slow

Low battery capacity - Charge the battery.
Battery will not hold charge - Service charging system or install new battery.
Bad battery terminals or disconnected wiring - Check cables and service or change terminals.

Starter doesn't crank

Battery is discharged or defective - Need to charge or replace the battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery power is low - Battery needs to be recharged.
Starter motor is damaged - Change or repair starter.