Caterpillar 272D3 XE Skid Steer Troubleshooting

The Caterpillar 272D3 XE skid steer loader driveline system components: a 231.9 cu.in (3.8L) Cat C3.8 DIT 4-cylinder turbocharged diesel engine with a rated power of 105.9 hp (79 kW), and 2-speed hydrostatic transmission. The hydraulic system has a high flow XPS pump with a rated capacity of 32 gal/min (121 l/min). The system relief pressure is 4060 psi (280 bar). The Cat 272D3 XE is equipped with vertical-lift loader boom, 100HS roller chains, and 12x16.5 tires. The skid steer loader has a boom lifting force of 5550 lbs (2517 kg) and bucket breakout force of 7362 lbs (3340 kg). The rated operating capacity is 3700 lbs (1680 kg), and tipping load is 7400 lbs (3360 kg).

Engine Troubleshooting

Engine starts hard or won't start

Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Replace filter element.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Excessive valve clearance - Adjust valve clearance.
Fuel injection pump damage - Rebuild or install a new injection pump.

Engine starts but stalls suddenly

Air filter is plugged - Change or service air filter element.
Fuel filter element is clogged - Clean or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Inspect fuel injectors and change as required.
Damaged fuel injection pump - Repair or replace injection pump.

Engine stalls during operation

Engine is cold - Warm up to required temperature.
Dirty fuel filter - Clean the filter or install new filter element.
There is air in the fuel system - Bleed the system.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Improper fuel injection timing - Set up as recommended.

Engine stops at low idle speed

Incorrect low idle setting - Normalize low idle speed.
Fuel injection pump is not operating properly - Replace or repair injection pump.
Fuel injectors are dirty or defective - Replace fuel injectors.
Improper valve clearance - Correct valve clearance.

Diesel power loss

Air filter is dirty - Service or replace the air filter.
Defective injection nozzle - Inspect nozzles and replace if necessary.
Incorrect fuel injection pressure - Adjust to proper pressure.
Valve out of adjustment - Need to adjust valve clearance.
Low idle speed setting is incorrect - Adjust low idle speed.
Fuel hoses or lines are dirty - Clean fuel system hoses and lines.
Cylinder head gasket defective - Replace cylinder head gasket.
Piston rings are damaged or leaking - Change piston rings.

Engine overheating

Engine coolant is insufficient - The cooling system needs to be refilled and checked for faults.
Engine oil insufficient - Fill up the oil to required level.
Damaged radiator cap or dirty radiator core - Clean radiator or change cap.
Fan belt is loose or defective - Belt replacement is recommended.
Engine overload - Load reducing is recommended.

Low oil pressure

Oil level is low - Checking oil level and add if necessary.
Engine oil filter is plugged - Change or service engine oil filter.
Incorrect oil viscosity - Fill up with the correct oil viscosity.
Crankshaft bearing has incorrect oil clearance - Bearings need to be reinstalled.
Defective oil pump - Replace as required.

Abnormal engine knocking or noise

Engine oil level low - Fill the crankcase with engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Improper setting of fuel injection pump timing - Adjust as recommended.
Incorrectly set low idle speed - Test and adjust.
Damaged or clogged injectors - Replace or clean fuel injectors.
Faulty or misaligned connecting rod - Connecting rod needs to be replaced or aligned.
Scored or worn pistons - Pistons replacement required.

Drive System Troubleshooting

Machine will not move in either direction or one direction

Hydraulic oil is insufficient - Check and refill the hydraulic oil.
Worn drive chain - Check drive chain and change defective parts.
Input drive shaft is worn - Rebuild or change.
Defective or worn relief valve - Repair or replace.
Hydraulic filter or suction line is plugged - Replace hydraulic filter or clean suction line.
Damaged or worn hand or foot controls - Check and repair as required.
Drive motor or pump failure - Change or repair faulty component.

Loss of power

Dirty hydraulic oil filter - Replace or clean hydraulic filter.
Relief valve is worn or opened - Close or replace relief valve.
Transmission components are worn or defective - Inspect and change defective parts.
Input drive shaft is worn - Faulty drive shaft need to be replaced or repair.
Air trapped in hydraulic system - Bleed hydraulic system.

Drive system overheats

Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Hydraulic fluid filter is clogged - Change or clean hydraulic filter.
Faulty relief valve - Service or change relief valve.
Damaged drive pump or hydraulic motor - Check and repair if required.
Hydraulic oil cooler is dirty - Cooling fins should be cleaned.
Drive system overloaded continuously - Load should be reduced.

Excessive noise

Improper oil viscosity - Drain and refill with proper oil.
Air in the hydraulic system - Need to bleed air.
Drive pump or hydraulic motor is damaged - Repair or change faulty component.
Worn or damaged mechanical components of drive system - Inspect the components for worn or defect and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheats

Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Main relief valve improper adjustment or failure - Adjust or replace the relief valve.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Hydraulic oil level is insufficient - Fill the hydraulic system with oil.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Lift arm does not lower or raise

Lift controls malfunction - Inspect and repair if necessary.
Damaged hydraulic oil pump - Install new pump or repair it.
Defective hydraulic control valve - Install a new valve or repair it.
Broken hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.

Bucket can't tilt

Defective bucket controls - Check and repair as required.
Hydraulic pump malfunction - Repair or change pump if required.
Faulty hydraulic control valve - Replace or repair the valve.
Bucket cylinder is faulty - Install a new cylinder or repair it.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Bucket or lift arm functions slowly

Defective hydraulic pump - Flow-rate pump and change pump if necessary.
Hydraulic cylinder oil leakage - Cylinder seals need to be replaced.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is unadjusted or worn - Repair or adjust correctly.
Low hydraulic pressure - Correct setting is required.

Bucket or boom jerks when working

Air in the hydraulic system - Bleed air from system.
Hydraulic oil filter element clogging - Clean or install new filter.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Scratched cylinder rod or tube - Change failed component.

Hydraulic pump is noisy

Hydraulic leakage or low oil level - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Clean or install new filter.
Dirty suction line - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Remove air from hydraulics.
Worn pump components - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged

Corroded or loose electrical wire connections - Service or tighten connections.
Electrical terminal connectors are faulty - Change terminal connectors.
Battery is defective - Use a new battery.
Loose or worn belt - Need to adjust belt tension or replace belt.

Starter turns slowly

Low battery voltage - Battery is drained, recharge it.
Battery is draining quickly - Battery needs to be serviced or replaced.
Bad battery terminals or disconnected wiring - Check cables and clean or change terminals.

Starter will not crank

Battery is discharged or defective - Replace or charge as required.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery capacity - Low battery charging, charge as required.
Damaged starter motor - Replace or repair starter.