Caterpillar 272D3 Skid Steer Troubleshooting

The Caterpillar 272D3 skid steer loader is powered by 231.9 cu.in (3.8L) Cat C3.8 DIT 4-cycle 4-cylinder direct injection turbocharged diesel engine with a rated power of 94.7 hp (70.6 kW) at 2400 rpm. The Cat 272D3 is equipped with a two-speed hydrostatic transmission, vertical-lift loader boom, 100HS continuous roller chains, and 12x16.5 tires. The hydraulic system has a standard pump with fluid flow rate of 23 gpm (86 lpm). The hydraulic pressure is 3335 psi (230 bar). The skid steer has a rated operating capacity of 3450 lbs (1570 kg) and tipping load of 6900 lbs (3140 kg). The boom lifting force is 5777 lbs (2620 kg), and bucket breakout force is 7443 lbs (3375 kg).

Engine Troubleshooting

Engine starts hard or doesn't start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is clogged - Replace the filter element.
Fuel injection nozzles are clogged or faulty - Clean or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Adjustment procedure required.
Fuel injection pump is damaged - Replace or rebuild injection pump.

Diesel starts and stops

Dirty air cleaner - Clean or replace element.
Fuel filter plugging - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Dirty or defective injectors - Replace fuel injectors.
Fuel injection pump malfunction - Install a new fuel pump or repair.

Engine stops running suddenly

Engine has not warmed up to recommended temperature - Warm up the engine.
Fuel filter plugging - Replace the filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Clogged or defective injection nozzles - Clean or replace injection nozzles.
Improper fuel injection timing - Adjust as recommended.

Engine stalls at idle

Improperly adjusted low idle speed - Adjust the low idle speed.
Fuel injection pump is not working correctly - Install a new fuel pump or repair.
Fuel injector fault - Change or clean fuel injectors.
Valve clearance is out of adjustment - Need to adjust valve clearance.

Loss of engine power

Air filter is plugged - Clean or change filter.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Insufficient fuel injection pressure - Adjust pressure to proper level.
The valve clearance is incorrect - Correct valve clearance needs to be set.
Incorrect low idle speed adjustment - Correct low idle settings.
Dirt in the fuel hoses or lines - Clean fuel hoses and lines.
Worn cylinder head gasket - Replace cylinder head gasket.
Worn or broken piston rings - Piston rings replacement required.

Engine overheating

Lack of engine coolant - Fill the cooling system and check components for leaks or other faults.
Engine oil level is insufficient - Check oil level and add oil as required.
Clogged radiator fins or leaking radiator cap - Change cap or clean radiator.
Broken or loose fan belt - Install new fan belt.
Diesel engine is overloaded - Reduce load on the engine.

Oil pressure is insufficient

Oil level is low - Add oil as required.
Dirty oil filter element - Change or clean engine oil filter element.
Incorrect engine oil Use oil of proper viscosity.
Excessive oil clearance of crankshaft bearing - Install new bearings.
Oil pump failure - Inspect and change as required.

Engine noises or knocks

Lack of engine oil - Fill up the oil to required level.
Coolant temperature is low - Warm up engine as required.
Wrong setting of fuel injection pump timing - Set it up as required.
Low idle speed set incorrectly - Adjust low idle speed.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Connecting rod is defective or not aligned - Need to align or replace the connecting rod.
Piston wear or scoring - Replace the pistons.

Drive System Troubleshooting

Machine does not move forward or backward

Hydraulic fluid is insufficient - Check and refill the hydraulic fluid.
Drive chain malfunction - Inspect drive chain and replace defective components.
Input drive shaft is faulty - Change or repair.
Relief valve is worn or damaged - Repair or replace relief valve.
Dirty suction line or hydraulic filter - Clean suction line or replace hydraulic filter.
Defective hand or foot controls - Repair or replace.
Damaged drive pump or motor - Inspect and replace as necessary.

Reduced power

Hydraulic oil filter is plugged - Check, clean, or replace as required.
Opened or worn relief valve - Close or replace relief valve.
Worn or defective transmission parts - Inspect and replace defective parts.
Defective input drive shaft - Repair or replace drive shaft.
Air in the hydraulic system - Bleed air from system.

Overheated drive system

Low hydraulic fluid level - Fill up the hydraulic fluid.
Dirty hydraulic fluid filter - Replace or clean hydraulic filter.
Stuck relief valve - Repair or replace.
Defective drive pump or hydraulic motor - Inspect and change as required.
Oil cooler is clogged - Cooling fins should be cleaned.
Overloaded drive system - Reduce drive system load.

Drive system makes excessive noise

Incorrect oil viscosity - Use oil of proper viscosity.
Hydraulic system is leaking air - Bleed air from system.
Hydraulic motor or drive pump failure - Check and repair if required.
Mechanical components of drive system are defective or worn - Check the parts for defect or damage and change if required.

Hydraulics Troubleshooting

Hydraulic system is overheated

Hydraulic pressure is not adjusted correctly - Set pressure correctly.
Unadjusted or defective main relief valve - Adjust relief valve or change if required.
Contaminated hydraulic oil - Change hydraulic oil.
Hydraulic fluid level is low - Check and refill the hydraulic fluid.
Hydraulic pump is defective - Repair or install new hydraulic pump.

Lift arm can't drop or lift

Defective lift controls - Check and repair as required.
Hydraulic pump not working - Repair or change pump if required.
Hydraulic control valve is defective - Repair or replace the valve.
Damaged hydraulic cylinder - Replace or repair boom cylinder.
Hydraulic oil is insufficient - Need to add oil.

Bucket does not function

Bucket tilt controls are defective - Repair or change.
Defective hydraulic pump - Replace or repair pump if necessary.
Faulty hydraulic control valve - Repair or replace the valve.
Defective bucket cylinder - Repair or replace cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Slow boom or bucket action

Hydraulic pump is defective - Check pump flow and install new pump if necessary.
Hydraulic cylinder oil leakage - Repair leak by replacing the seals.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Defective or not adjusted hydraulic control valve - Set properly or repair.
Low hydraulic pressure - Set pressure correctly.

Lift arm or bucket jerks when working

Air trapped in hydraulic system - Air bleeding is required.
Hydraulic oil filter element clogging - Change or clean oil filter.
Hydraulic fluid is contaminated - Change hydraulic fluid.
Scored cylinder tube or rod - Replace worn component.

Excessive hydraulic pump noise

Hydraulic leaks or low oil level - Add hydraulic oil or correct system leaks.
Hydraulic filter is clogged - Replace or clean the filter.
Suction line is dirty - Clean suction line as required.
Air enters the pump - Need to bleed air.
Pump parts are faulty - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery will not charge

Wiring connections are loose or corroded - Clean or tighten wiring connections.
Defective battery terminal clamps - Change terminal clamps.
Defective battery - Install a new battery.
Loose or damaged belt - Replace belt or adjust belt tension.

Starter turning slow

Low battery power - Charge the battery.
Battery does not hold charge - Service battery or change it.
Wires are disconnected or battery terminals are corroded - Check wiring and clean or replace terminals.

Starter motor is not working

Battery is drained or worn - Charge or change the battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery voltage - Recharge the battery.
Starter motor failing - Repair or change starter.