Caterpillar 289D Track Loader Troubleshooting

The Caterpillar 289D compact track loader is powered by 203.1 cu.in (3.3L) Cat C3.3B DIT 4-cylinder turbo diesel engine with a rated power of 71.8 hp (53.6 kW). The Caterpillar 289D is equipped with a two-speed hydro transmission, vertical-lift loader boom, and 15.7" (400 mm) or 17.7" (400 mm) rubber tracks. The hydraulic system has a pump with fluid flow rate of 23 gpm (86 lpm) or 32 gpm (121 lpm). The hydraulic pressure is 3335 psi (230 bar) or 4060 psi (280 bar). The loader has a rated operating capacity of 2660 lbs (1207 kg) and tipping load of 7600 lbs (3448 kg). The boom lifting force is 5023 lbs (2278 kg), and bucket breakout force is 7290 lbs (3307 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start

Air in the fuel system - Air bleeding.
Dirty fuel filter - Change filter element.
Fuel injection nozzles are faulty or clogged - Change fuel injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is incorrect - Check and adjust as required.
Fuel injection pump is faulty - Repair or install a new fuel pump.

Diesel starts but stalls immediately

Air cleaner is dirty - Service or replace air cleaner.
Clogged fuel filter - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are faulty or clogged - Replace fuel injectors.
Damaged fuel injection pump - Change pump or rebuild it.

Engine stops suddenly during operation

Engine has not warmed up to recommended temperature - Warm up the engine as required.
Fuel filter element is clogged - Change filter element.
Air in fuel tank - Bleed fuel tank.
Clogged injection nozzle - Check injection nozzles and replace if required.
Incorrect adjustment of fuel injection pump timing - Adjust according to specifications.

Engine stalls while idle

Low idle speed set incorrectly - Adjust as required.
Fuel injection pump malfunction - Repair or install a new fuel pump.
Dirty or defective injectors - Replace or clean fuel injectors.
The valve clearance is not adjusted - Check and adjust.

Diesel power loss

Plugged air filter - Service or replace the air filter.
Clogged injection nozzle - Check injection nozzles and replace if required.
Insufficient fuel injection pressure - Correct the pressure settings.
Valve out of adjustment - Adjust to proper valve clearance.
Low idle speed setting is incorrect - Normalize low idle speed.
Dirt in the fuel lines or hoses - Clean fuel lines and hoses.
Cylinder head gasket is worn - Install new cylinder head gasket.
Worn or broken piston rings - Replace piston rings.

Engine is overheated

Insufficient coolant fluid - Top up coolant fluid and check system for leaks.
Not enough engine oil - Fill up the engine oil.
Dirty radiator fins or defective radiator cap - Replace cap or clean radiator.
Fan belt is broken or worn - Change as required.
Diesel engine overloaded - Reduce load on the engine.

Oil pressure is insufficient

Not enough oil in the engine - Fill up the engine oil.
Engine oil filter is plugged - Change or service engine oil filter.
Oil grade or viscosity is incorrect - Use the specified type of engine oil.
Excessive main bearing oil clearance - Bearing replacement required.
Oil pump malfunction - Check and replace if necessary.

Engine knocks or noises

Insufficient engine oil - Fill up the engine oil.
Engine is not warmed up to required temperature - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Set it up as required.
Low idle speed setting is incorrect - Need to adjust idle speed.
Fuel injector fault - Replace fuel injectors.
Connecting rod failure or misalignment - Alignment procedure or replacement is required.
Pistons are worn or scored - Install new pistons.

Drive System Troubleshooting

Drive system won't operate in either direction

Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Blocked or defective track mechanism - Remove blockage or repair tracks.
Worn or defective relief valve - Repair or change.
Clogged hydraulic filter or suction line - Service suction line or change hydraulic filter.
Damaged or worn hand or foot controls - Repair or replace.
Drive pump or motor malfunction - Replace or repair faulty component.

Machine is not driving straight or driving is jerky

Track mechanism is defective or jammed - Fix jamming or repair tracks.
Tracks are loose or faulty - Adjust track tension as required or replace tracks.
Track frame is clogged with debris, dirt, or foreign objects - Remove foreign objects or debris and clean undercarriage track frame.

Lack of power

Dirty hydraulic oil filter - Check, clean, or replace as required.
Relief valve is worn or opened - Close or replace relief valve.
Transmission parts are worn or defective - Inspect and change defective parts.
Input drive shaft is defective - Rebuild or change the shaft.
Air in hydraulic system - Bleed air from hydraulic system.

Drive system overheats

Hydraulic fluid level low - Add fluid as required.
Hydraulic fluid filter is clogged - Change or service hydraulic filter.
Relief valve defective or worn - Repair or change.
Defective drive pump or hydraulic motor - Replace or repair faulty component.
Dirty oil cooler - Cooling fins should be cleaned.
Overloaded drive system - Reduce drive system load.

Drive system makes excessive noise

Improper oil viscosity - Drain and refill with correct oil.
Air in the hydraulic system - Need to bleed air.
Damaged drive pump or hydraulic motor - Replace or repair 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 overheats

Incorrect hydraulic pressure setting - Correct adjustment is required.
Main relief valve failure or improper setting - Adjust or replace the relief valve.
Dirty hydraulic fluid - Hydraulic fluid change required.
Not enough hydraulic oil in the system - Fill up the hydraulic oil.
Hydraulic pump is faulty - Change or repair hydraulic pump if required.

Lift arm won't raise or lower

Defective lift controls - Change or repair.
Hydraulic pump malfunction - Change or repair hydraulic pump if required.
Damaged hydraulic control valve - Repair or change hydraulic valve.
Defective hydraulic cylinder - Change or repair lift cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket won't move

Bucket tilt controls are defective - Change or repair.
Hydraulic pump not working - Replace or repair pump if necessary.
Defective hydraulic control valve - Install a new hydraulic valve or repair it.
Damaged bucket cylinder - Replace or repair cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Slow boom or bucket operation

Hydraulic pump is defective - Check pump performance and change it if necessary.
Hydraulic cylinder leaking - Cylinder seals need to be replaced.
Hydraulic fluid level low - Add fluid as required.
Hydraulic control valve is unadjusted or worn - Repair or adjust correctly.
Low hydraulic pressure - Set pressure correctly.

Lift arm or bucket jerks when working

Air leaks in hydraulic system - Need to bleed air.
Plugged hydraulic oil filter - Clean or install new filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Scratched cylinder rod or tube - Replace damaged component.

Hydraulic pump is noisy

Insufficient oil level or leaking hydraulic system - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter clogging - Replace or clean the filter.
Suction line clogging - Clean suction line as required.
Pump is sucking air - Bleed air from hydraulics.
Pump parts are faulty - Replace or rebuild the pump.

Electrical Troubleshooting

Battery does not charge

Loose or corroded wire connections - Tighten or clean connections.
Electrical terminal connectors are faulty - Install new terminal connectors.
Dead cell in battery - Battery replacement required.
Defective or loose belt - Adjust belt tension or change the belt.

Starter motor cranks slow

Battery voltage is low - Battery needs to be recharged.
Battery drains quickly - Service or change the battery.
Battery cables are disconnected or terminals are faulty - Check cables and clean or change terminals.

Starter is not working

Battery is discharged or defective - Need to charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery output - Low battery charging, charge as required.
Starter motor failing - Repair or install a new starter.