Service manual Caterpillar 239D3 Compact Track Loader with C2.2 Engine | K5S00001-UP

239D3 and 249D3 Compact Track Loaders and 226D3 and 232D3 Skid Steer Loaders
– Accumulator (Pilot) – Test and Charge
– Accumulator (Ride Control) – Test and Charge
– Air Conditioner – Mounting
– Air Conditioner Lines
– Auxiliary Hydraulic Lines
– Auxiliary Hydraulic Lines
– Bank Valve
– Cab Door
– Console Cover
– Control Manifold – Quick Coupler
– Control Valve (Implement)
– Control Valve (Work Tool)
– Coupler Cylinder
– Coupler Lines
– Coupler Lines
– Cover Plate – Mounting
– Cover Plate – Mounting
– Cutting Edge
– Electrohydraulic Control (Joystick)
– Electrohydraulic System
– Engine Enclosure
– Engine Mounting
– Engine Speed Control
– Gear Motor
– Gear Motor (Fan) – Test
– Gear Motor (Fan, Demand)
– Gear Pump
– Gear Pump
– Gear Pump – Charge Oil
– General Information
– Governor Pedal
– Heater Lines
– Hydraulic Fan System
– Hydraulic Lines
– Hydraulic Oil Contamination – Test
– Hydraulic Oil Filter
– Hydraulic Oil Temperature – Check
– Hydraulic System Troubleshooting – Implement
– Hydraulic Tank and Mounting
– Hydraulic Tank and Mounting
– Hydrostatic Lines
– Hydrostatic Lines
– Hydrostatic Lines
– Hydrostatic Motor and Mounting
– Hydrostatic Motor and Mounting
– Hydrostatic System
– Hydrostatic System – Flush and Fill
– Hydrostatic System – Test and Adjust
– Hydrostatic System Troubleshooting
– Idler Wheel
– Implement System – Test – Pressure
– Lift Arm Cylinder and Mounting
– Lift Arm Group
– Lift Cylinder
– Lift Cylinder
– Line Relief Valve – Test
– Lines (Lift Cylinder)
– Lines (Lift Cylinder)
– Lines (Tilt Cylinder)
– Lines (Tilt Cylinder)
– Loader Frame
– Loader Frame
– Low Pressure Fuel System
– Machine Lifting Group
– Machine Preparation
– Main Relief Valve – Adjust
– Operational Checks
– Pedal Control and Mounting
– Pilot System Pressure – Test
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor (Hydrostatic)
– Piston Motor – Mounting
– Piston Pump (Hydrostatic)
– Piston Pump (Hydrostatic)
– Pressure Reducing Valve (Quick Coupler) – Test and Adjust
– Pressure Tap Locations
– Pump Flow – Test
– Pump Lines
– Pump Lines
– Pump Mounting
– Pump Mounting (Hydrostatic)
– Quick Coupler
– Quick Coupler
– Quick Coupler
– Quick Coupler Pins Do Not Engage and/or Disengage
– Quick Coupler System – If Equipped
– Radiator
– Radiator and Hydraulic Oil Cooler
– Refrigerant Compressor
– Refrigerant Condenser and Mounting
– Ride Control Accumulator
– Ride Control System – If Equipped
– ROPS Mounting
– Seat and Mounting
– Sprocket
– System Pressure – Release
– Tandem Drive
– Tandem Drive and Axle
– Tilt Cylinder – Left Hand
– Tilt Cylinder – Right Hand
– Tire and Rim
– Track Adjuster and Recoil
– Track Idler – Double Flange
– Track Idler – Single Flange
– Track Roller
– Track Roller Frame
– Undercarriage
– Undercarriage Axle and Mounting
– Visual Inspection
– Work Tool Hydraulic System
D-Series, D2-Series and D3-Series Compact Track Loaders, Multi Terrain Loaders, and Skid Steer Loaders Machine Electronic Control System
– Calibration
– Connector Locations
– Data Link
– Diagnostic Capabilities
– Diagnostic Code List
– Electrical Connector – Inspect
– Electrical Input Components
– Electrical Output Components
– Electronic Control Module
– Electronic Control Module (ECM) – Configure
– Electronic Control Module (ECM) – Flash Program
– Electronic Control Module (ECM) – Replace
– Emerging Symptom Information
– Event Code List
– Features
– General Information
– General Information
– MID 039 – CID 0041 – FMI 03
– MID 039 – CID 0041 – FMI 04
– MID 039 – CID 0070 – FMI 03
– MID 039 – CID 0070 – FMI 04
– MID 039 – CID 0091 – FMI 03
– MID 039 – CID 0091 – FMI 04
– MID 039 – CID 0091 – FMI 08
– MID 039 – CID 0091 – FMI 13
– MID 039 – CID 0096 – FMI 03
– MID 039 – CID 0096 – FMI 04
– MID 039 – CID 0110 – FMI 03
– MID 039 – CID 0110 – FMI 04
– MID 039 – CID 0144 – FMI 03
– MID 039 – CID 0144 – FMI 05
– MID 039 – CID 0144 – FMI 06
– MID 039 – CID 0168 – FMI 02
– MID 039 – CID 0168 – FMI 03
– MID 039 – CID 0168 – FMI 04
– MID 039 – CID 0190 – FMI 02
– MID 039 – CID 0190 – FMI 08
– MID 039 – CID 0262 – FMI 03
– MID 039 – CID 0262 – FMI 04
– MID 039 – CID 0268 – FMI 02
– MID 039 – CID 0346 – FMI 03
– MID 039 – CID 0346 – FMI 05
– MID 039 – CID 0346 – FMI 06
– MID 039 – CID 0350 – FMI 03
– MID 039 – CID 0350 – FMI 04
– MID 039 – CID 0350 – FMI 08
– MID 039 – CID 0354 – FMI 03
– MID 039 – CID 0354 – FMI 05
– MID 039 – CID 0354 – FMI 06
– MID 039 – CID 0354 – FMI 13
– MID 039 – CID 0355 – FMI 03
– MID 039 – CID 0355 – FMI 05
– MID 039 – CID 0355 – FMI 06
– MID 039 – CID 0355 – FMI 13
– MID 039 – CID 0356 – FMI 03
– MID 039 – CID 0356 – FMI 05
– MID 039 – CID 0356 – FMI 06
– MID 039 – CID 0356 – FMI 13
– MID 039 – CID 0357 – FMI 03
– MID 039 – CID 0357 – FMI 05
– MID 039 – CID 0357 – FMI 06
– MID 039 – CID 0357 – FMI 13
– MID 039 – CID 0358 – FMI 03
– MID 039 – CID 0358 – FMI 05
– MID 039 – CID 0358 – FMI 06
– MID 039 – CID 0364 – FMI 03
– MID 039 – CID 0364 – FMI 04
– MID 039 – CID 0364 – FMI 08
– MID 039 – CID 0367 – FMI 03
– MID 039 – CID 0367 – FMI 04
– MID 039 – CID 0444 – FMI 03
– MID 039 – CID 0444 – FMI 05
– MID 039 – CID 0444 – FMI 06
– MID 039 – CID 0458 – FMI 03
– MID 039 – CID 0458 – FMI 04
– MID 039 – CID 0458 – FMI 08
– MID 039 – CID 0485 – FMI 03
– MID 039 – CID 0485 – FMI 05
– MID 039 – CID 0485 – FMI 06
– MID 039 – CID 0486 – FMI 04
– MID 039 – CID 0490 – FMI 03
– MID 039 – CID 0490 – FMI 04
– MID 039 – CID 0598 – FMI 03
– MID 039 – CID 0598 – FMI 05
– MID 039 – CID 0598 – FMI 06
– MID 039 – CID 0600 – FMI 03
– MID 039 – CID 0600 – FMI 04
– MID 039 – CID 0681 – FMI 03
– MID 039 – CID 0681 – FMI 05
– MID 039 – CID 0681 – FMI 06
– MID 039 – CID 0682 – FMI 03
– MID 039 – CID 0682 – FMI 05
– MID 039 – CID 0682 – FMI 06
– MID 039 – CID 1007 – FMI 02
– MID 039 – CID 1007 – FMI 03
– MID 039 – CID 1007 – FMI 04
– MID 039 – CID 1076 – FMI 03
– MID 039 – CID 1076 – FMI 05
– MID 039 – CID 1076 – FMI 06
– MID 039 – CID 1076 – FMI 13
– MID 039 – CID 1190 – FMI 04
– MID 039 – CID 1251 – FMI 04
– MID 039 – CID 1551 – FMI 03
– MID 039 – CID 1551 – FMI 05
– MID 039 – CID 1551 – FMI 06
– MID 039 – CID 1627 – FMI 03
– MID 039 – CID 1627 – FMI 05
– MID 039 – CID 1627 – FMI 06
– MID 039 – CID 1628 – FMI 03
– MID 039 – CID 1628 – FMI 04
– MID 039 – CID 1703 – FMI 03
– MID 039 – CID 1703 – FMI 05
– MID 039 – CID 1703 – FMI 06
– MID 039 – CID 1703 – FMI 13
– MID 039 – CID 1704 – FMI 03
– MID 039 – CID 1704 – FMI 05
– MID 039 – CID 1704 – FMI 06
– MID 039 – CID 1704 – FMI 13
– MID 039 – CID 1705 – FMI 03
– MID 039 – CID 1705 – FMI 05
– MID 039 – CID 1705 – FMI 06
– MID 039 – CID 1705 – FMI 13
– MID 039 – CID 1706 – FMI 03
– MID 039 – CID 1706 – FMI 05
– MID 039 – CID 1706 – FMI 06
– MID 039 – CID 1706 – FMI 13
– MID 039 – CID 1936 – FMI 03
– MID 039 – CID 1936 – FMI 05
– MID 039 – CID 1936 – FMI 06
– MID 039 – CID 1939 – FMI 03
– MID 039 – CID 1939 – FMI 05
– MID 039 – CID 1939 – FMI 06
– MID 039 – CID 2204 – FMI 03
– MID 039 – CID 2204 – FMI 04
– MID 039 – CID 2204 – FMI 08
– MID 039 – CID 2211 – FMI 03
– MID 039 – CID 2211 – FMI 05
– MID 039 – CID 2211 – FMI 06
– MID 039 – CID 2212 – FMI 03
– MID 039 – CID 2212 – FMI 05
– MID 039 – CID 2212 – FMI 06
– MID 039 – CID 2246 – FMI 03
– MID 039 – CID 2246 – FMI 05
– MID 039 – CID 2246 – FMI 06
– MID 039 – CID 2471 – FMI 03
– MID 039 – CID 2471 – FMI 04
– MID 039 – CID 2474 – FMI 03
– MID 039 – CID 2474 – FMI 04
– MID 039 – CID 2474 – FMI 08
– MID 039 – CID 2474 – FMI 13
– MID 039 – CID 2475 – FMI 03
– MID 039 – CID 2475 – FMI 04
– MID 039 – CID 2475 – FMI 08
– MID 039 – CID 2475 – FMI 13
– MID 039 – CID 2476 – FMI 03
– MID 039 – CID 2476 – FMI 04
– MID 039 – CID 2476 – FMI 08
– MID 039 – CID 2476 – FMI 13
– MID 039 – CID 2477 – FMI 03
– MID 039 – CID 2477 – FMI 04
– MID 039 – CID 2477 – FMI 08
– MID 039 – CID 2477 – FMI 13
– MID 039 – CID 2669 – FMI 03
– MID 039 – CID 2669 – FMI 04
– MID 039 – CID 2671 – FMI 03
– MID 039 – CID 2671 – FMI 04
– MID 039 – CID 2671 – FMI 05
– MID 039 – CID 2685 – FMI 02
– MID 039 – CID 2685 – FMI 08
– MID 039 – CID 2686 – FMI 02
– MID 039 – CID 2686 – FMI 08
– MID 039 – CID 2687 – FMI 02
– MID 039 – CID 2687 – FMI 08
– MID 039 – CID 2688 – FMI 02
– MID 039 – CID 2688 – FMI 08
– MID 039 – CID 2795 – FMI 03
– MID 039 – CID 2795 – FMI 04
– MID 039 – CID 2795 – FMI 08
– MID 039 – CID 2795 – FMI 13
– MID 039 – CID 3514 – FMI 09
– MID 039 – CID 3700 – FMI 03
– MID 039 – CID 3700 – FMI 04
– MID 039 – CID 3700 – FMI 08
– MID 039 – CID 3700 – FMI 13
– MID 039 – CID 3915 – FMI 03
– MID 039 – CID 3915 – FMI 04
– MID 039 – CID 5001 – FMI 03
– MID 039 – CID 5001 – FMI 04
– MID 039 – CID 5001 – FMI 08
– MID 039 – CID 5001 – FMI 13
– MID 039 – CID 5002 – FMI 03
– MID 039 – CID 5002 – FMI 04
– MID 039 – CID 5002 – FMI 08
– MID 039 – CID 5002 – FMI 13
– Motor Speed Is Unexpected
– Power Supply Circuit of Electronic Control Module
– Pulse Width Modulated Sensor
– Service Tools
– Starting System
– Switch Circuits
– Symptom Troubleshooting
– System Schematic
– System Schematic
– Using Caterpillar Electronic Technician to Determine
– Using the Operator Monitor to Determine Diagnostic Codes
– Wiring Harness (Open Circuit) – Test
– Wiring Harness (Short Circuit) – Test
Disassembly and Assembly 239D3 and 249D3 Compact Track Loaders and 226D3 and 232D3 Skid Steer Loaders Power Train
– Axle – Assemble
– Axle – Disassemble
– Axle – Remove and Install
– Axle – Remove and Install
– Chain (Drive) – Remove and Install
– Chain (Drive) Tension – Adjust
– Duo-Cone Seals – Install
– Duo-Cone Seals – Install
– Hose Coupling – Disconnect and Connect – Threadless
– Idler – Assemble
– Idler – Disassemble
– Idler – Remove and Install – Front
– Idler – Remove and Install – Rear
– Piston Motor (Hydrostatic) – Assemble – CTL
– Piston Motor (Hydrostatic) – Assemble – SSL One Speed
– Piston Motor (Hydrostatic) – Assemble – Two Speed SSL
– Piston Motor (Hydrostatic) – Disassemble – CTL
– Piston Motor (Hydrostatic) – Disassemble – SSL One Speed
– Piston Motor (Hydrostatic) – Disassemble – Two Speed SSL
– Piston Motor (Hydrostatic) – Remove and Install – CTL
– Piston Motor (Hydrostatic) – Remove and Install – SSL
– Piston Pump (Hydrostatic) – Assemble
– Piston Pump (Hydrostatic) – Disassemble
– Piston Pump (Hydrostatic) – Remove and Install
– Recoil Spring – Assemble
– Recoil Spring – Disassemble
– Recoil Spring and Track Adjuster – Remove and Install
– Sprocket – Remove and Install
– System Pressure – Release
– Tire and Rim – Remove and Install
– Track – Remove and Install
– Track Roller – Remove and Install
– Undercarriage – Remove and Install
– Undercarriage – Remove and Install
Disassembly and Assembly 239D3 and 249D3 Compact Track Loaders and 226D3 and 232D3 Skid Steer Loaders. Machine Systems
– Accumulator Manifold and Solenoid Mounting (Pilot Shutoff) –
– Air Conditioner and Heater – Remove and Install
– Blower Motor – Remove and Install
– Cab – Remove and Install
– Cab – Tilt
– Cable – Remove and Install – Dead Engine Lower Control Valve
– Control Valve (Work Tool) – Assemble – Standard and High
– Control Valve (Work Tool) – Disassemble – Standard and High
– Control Valve (Work Tool) – Remove and Install
– Coupler Cylinder – Remove and Install
– Electrohydraulic Control (Joystick) – Remove and Install
– Gas Spring – Remove and Install
– Gear Pump – Assemble – Charge Pump
– Gear Pump – Assemble – High Flow
– Gear Pump – Assemble – Standard Flow
– Gear Pump – Disassemble – Charge Pump
– Gear Pump – Disassemble – High Flow
– Gear Pump – Disassemble – Standard Flow
– Gear Pump – Remove and Install – Charge Pump
– Gear Pump – Remove and Install – High Flow
– Gear Pump – Remove and Install – Standard Flow
– Governor Pedal – Remove and Install
– Hydraulic Accumulator (Pilot Oil) – Remove and Install
– Hydraulic Oil Filter Base – Remove and Install
– Lift Arms – Remove and Install – Extended Reach
– Lift Arms – Remove and Install – Radial Lift
– Lift Cylinder – Remove and Install
– Quick Coupler – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser – Remove and Install
– Ride Control Valve – Remove and Install
– Seat – Remove and Install
– Sensor – Remove and Install – Rotary Sensor Extended Reach
– Sensor – Remove and Install – Rotary Sensor Radial Lift
– Tilt Cylinder – Remove and Install
– Window Wiper Motor – Remove and Install
Disassembly and Assembly 249D3 Compact Track Loader Engine Supplement
– Air Cleaner – Remove and Install
– Alternator – Remove and Install
– Battery – Remove and Install
– Cab – Tilt
– Coolant Tank – Remove and Install
– Crankcase Breather – Remove and Install
– Crankshaft Pulley – Remove and Install
– Diesel Oxidation Catalyst – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Control Module (ECM) – Remove and Install
– Engine – Remove and Install
– Engine Enclosure – Remove and Install
– Engine Oil Pan – Remove and Install
– Exhaust Cooler (NRS) – Remove and Install
– Exhaust Pipe – Remove and Install
– Fuel Cooler – Remove and Install
– Fuel Filter and Water Separator – Remove and Install
– Fuel Priming Pump – Remove and Install
– Gear Motor (Fan) – Assemble
– Gear Motor (Fan) – Disassemble
– Gear Motor (Fan) – Remove and Install
– Inlet Air Temperature Sensor – Remove and Install
– Pump Drive Coupling – Remove and Install
– Radiator and Aftercooler – Assemble
– Radiator and Aftercooler – Disassemble
– Radiator and Aftercooler – Remove and Install
– Radiator Guard – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Condenser – Remove and Install
– System Pressure – Release
– Temperature and Pressure Sensor (Air Inlet Manifold) –
– Temperature Sensor – Remove and Install
– Turbocharger – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
Disassembly and Assembly C1.7 and C2.2 Engines for Caterpillar Built Machines
– Alternator – Remove and Install – Flat-Belt
– Alternator – Remove and Install – V-Belt
– Bearing Clearance – Check
– Boost Pressure Sensor – Remove and Install
– Camshaft – Assemble
– Camshaft – Disassemble
– Camshaft – Install
– Camshaft – Remove
– Clean Emissions Module – Remove and Install
– Connecting Rod Bearings – Install – Connecting rods in position
– Connecting Rod Bearings – Remove – Connecting rods in
– Coolant Temperature Sensor – Remove and Install
– Crankcase Breather – Remove and Install – C1.7
– Crankcase Breather – Remove and Install – C2.2
– Crankshaft – Install
– Crankshaft – Remove
– Crankshaft Front Seal – Remove and Install
– Crankshaft Gear – Remove and Install
– Crankshaft Main Bearings – Install
– Crankshaft Main Bearings – Remove
– Crankshaft Pulley – Remove and Install
– Crankshaft Pulley – Remove and Install – Multi V-Belt
– Crankshaft Rear Seal – Remove and Install
– Crankshaft Rear Seal – Remove and Install – Engines Without a
– Crankshaft Wear Sleeve (Rear) – Remove and Install
– Cylinder Head – Install – C1.7
– Cylinder Head – Install – C2.2
– Cylinder Head – Remove – 4 Cylinder Engines
– Cylinder Head – Remove – C1.7
– Electric Starting Motor – Remove and Install
– Electronic Control Module – Remove and Install – Mounted Off
– Engine Lifting Bracket – Remove and Install
– Engine Oil Cooler – Remove and Install
– Engine Oil Line – Remove and Install
– Engine Oil Pan – Remove and Install – Steel Engine Oil Pan
– Engine Oil Pressure Sensor – Remove and Install – 3 Cylinder
– Engine Oil Pressure Sensor – Remove and Install – 4 Cylinder
– Engine Oil Pump – Install
– Engine Oil Pump – Remove
– Engine Oil Pump – Remove – 3 Cylinder Engines
– Engine Oil Relief Valve – Remove and Install
– Exhaust Cooler (NRS) – Remove and Install – 3 Cylinder Engines
– Exhaust Cooler (NRS) – Remove and Install – 4 Cylinder Engines
– Exhaust Elbow – Remove and Install – Exhaust Elbow between
– Exhaust Gas Recirculation Valve – Remove and Install
– Exhaust Manifold – Remove and Install – 3 Cylinder Engines
– Exhaust Manifold – Remove and Install – 4 Cylinder Engines
– Flywheel – Remove and Install
– Flywheel Housing – Remove and Install
– Fuel Filter Base – Remove and Install – Secondary Fuel Filter
– Fuel Injection Lines – Remove and Install – 3 Cylinder Engines
– Fuel Injection Lines – Remove and Install – 4 Cylinder Engines
– Fuel Injection Pump – Install
– Fuel Injection Pump – Remove
– Fuel Injection Pump Gear – Install
– Fuel Injection Pump Gear – Remove
– Fuel Injector – Remove and Install – Type 1 – Earlier Engines –
– Fuel Injector – Remove and Install – Type 2 – Later Engines – If
– Fuel Manifold (Rail) – Remove and Install – 3 Cylinder Engines
– Fuel Manifold (Rail) – Remove and Install – 4 Cylinder Engines
– Fuel Pressure Sensor – Remove and Install
– Fuel Temperature Sensor – Remove and Install
– Glow Plugs – Remove and Install
– Housing (Front) – Install
– Housing (Front) – Remove
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Remove and Install – 3 Cylinder Engines
– Inlet Manifold – Remove and Install – 4 Cylinder Engines
– Inlet Manifold Temperature Sensor – Remove and Install
– Lifter Group – Remove and Install
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Install
– Pistons and Connecting Rods – Remove
– Pressure Sensor (DPF) – Remove and Install – Differential
– Primary Engine Speed/Timing Sensor – Remove and Install
– Rocker Shaft – Assemble
– Rocker Shaft – Disassemble
– Rocker Shaft and Pushrod – Install
– Rocker Shaft and Pushrod – Remove
– Secondary Engine Speed/Timing Sensor – Remove and Install
– Support and Mounting (CEM) – Remove and Install
– Temperature Sensor (Exhaust) – Remove and Install –
– Throttle Valve (Intake Air) – Install
– Throttle Valve (Intake Air) – Remove
– Turbocharger – Install – 3 Cylinder Engines
– Turbocharger – Install – 4 Cylinder Engines
– Turbocharger – Remove – 3 Cylinder Engines
– Turbocharger – Remove – 4 Cylinder Engines
– V-Belts – Remove and Install
– Valve Mechanism Cover – Remove and Install – C1.7
– Valve Mechanism Cover – Remove and Install – C2.2
– Water Pump – Remove and Install
– Water Temperature Regulator Housing – Remove and Install
Schematic Caterpillar 226D3 and 232D3 Skid Steer Loader 239D3 and 249D3 Compact Track Loader Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– 021 (Orange) (Pilot Shutoff Circuit)
– 032 (Red) (Main Pump Output)
– 141 (Lt Orange) (Tilt Cylinder Circuit)
– 190 (Dk Pink) (Charge Pump Output)
– 258 (Dk Purple) (Hydraulic Fan Circuit)
– 347 (Dk Green) (Supply Line)
– 464 (Brown) (Quick Coupler Circuit)
– 577 (Lt Green) (Drain / Return Line)
– 613 (Dk Yellow) (Steering Circuit)
– 640 (Blue) (Travel Control Circuit)
– 5767 (Olive Green) (Lift Cylinder Circuit)
– CON 522 (Lt Purple/Black Stripe) (Coupler Cylinder Circuit)
– Machine Views
– Machine – Front View
– Machine – Right Side View
Schematic Caterpillar 226D3, 232D3, 239D3, 249D3 Electrical System
– Features
– Cover Page
– Information
– Component Location
– Vol 1 – Cab
– Vol 2 – Chassis and Engine
– Connector Location
– Vol 1 – Cab
– Vol 2 – Chassis and Engine
– Schematics
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– Vol 1 – Cab
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 021 (Orange) (Starting)
– 258 (Dk Purple) (Machine Control Circuit)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 346 (CAT D.L.)
– CON 509 (J1939/1587 D.L.)
– CON 522 (CAN “B” D.L.)
– SUB 651 (Blue Gray) (Ethernet)
– Vol 2 – Chassis and Engine
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Machine Control Circuit)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 509 (J1939/1587 D.L.)
– CON 190 (CAN “A” D.L.)
– CON 522 (CAN “B” D.L.)
– Machine Views
– Vol 1 – Cab
– Cab – Front View
– Cab – Front View (Without Seat)
– Cab – Rear View
– Cab – Right Side View
– Machine – Rear View
– Vol 2 – Chassis and Engine
– Chassis – Front Top View
– Chassis – Rear View
– Engine LH View
– Engine RH View
– Engine Top View
– Machine Right Side View (HVAC Wiring)
– Main Control Valve
Specifications C1.7 and C2.2 Engines for Caterpillar Built Machines
– Alternator and Regulator
– Belt Tension Chart
– Camshaft
– Connecting Rod
– Connecting Rod Bearing Journal
– Coolant Temperature Sensor
– Crankcase Breather
– Crankshaft
– Crankshaft Pulley
– Cylinder Block
– Cylinder Head
– Cylinder Head Valves
– Electric Starting Motor
– Engine Design
– Engine Design
– Engine Lifting Bracket
– Engine Oil Filter
– Engine Oil Lines
– Engine Oil Pan
– Engine Oil Pressure Switch
– Engine Oil Pump
– Engine Oil Relief Valve
– Exhaust Cooler (NRS)
– Exhaust Gas Valve (NRS)
– Exhaust Gas Valve (NRS) – Throttle Valve
– Exhaust Manifold
– Exhaust Manifold
– Fan Drive
– Flywheel
– Flywheel Housing
– Fuel Filter Base – Secondary Fuel Filter Base
– Fuel Injection Lines
– Fuel Injection Nozzles
– Fuel Injection Pump
– Fuel Manifold (Rail)
– Gear Group (Front)
– Glow Plugs
– Housing (Front)
– Inlet Manifold
– Inlet Manifold
– Inlet Manifold Temperature and Pressure Sensor
– Inlet Manifold Temperature Sensor
– Lifter Group
– Main Bearing Journal
– Piston and Rings
– Pressure Sensor (Exhaust Differential)
– Rocker Shaft
– Speed/Timing Sensor
– Temperature Sensor (DOC Inlet)
– Temperature Sensor (DPF Inlet)
– Turbocharger
– Valve Mechanism Cover
– Valve Mechanism Cover
– Water Temperature Regulator
Systems Operation & Testing and Adjusting C1.7 and C2.2 Engines for Caterpillar Built Machines
– Air in Fuel – Test
– Air Inlet and Exhaust System
– Air Inlet and Exhaust System – Inspect
– Alternator – Test
– Basic Engine
– Battery – Test
– Charging System – Test
– Clean Emissions Module
– Cleanliness of Fuel System Components
– Compression – Test
– Connecting Rod – Inspect
– Connecting Rod Bearings – Inspect
– Coolant Temperature Switch – Test – Coolant Temperature
– Cooling System
– Cooling System – Check – Overheating
– Cooling System – Inspect
– Cooling System – Test
– Cylinder Block – Inspect
– Cylinder Head – Inspect
– Electric Starting System – Test
– Electrical System
– Electronic Control System Components
– Engine Crankcase Pressure (Blowby) – Test
– Engine Oil Pressure – Test
– Engine Oil Pressure Switch – Test
– Engine Oil Pump – Inspect
– Engine Valve Lash – Inspect/Adjust
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Exhaust Cooler (NRS) – Test
– Exhaust Temperature – Test
– Finding Top Center Position for No. 1 Piston
– Flywheel – Inspect
– Flywheel Housing – Inspect
– Fuel Injection Timing – Check
– Fuel Quality – Test
– Fuel System – Engines with a Single Fuel Filter
– Fuel System – Engines with Two Fuel Filters and Electric Fuel
– Fuel System – Inspect
– Fuel System – Prime
– Gear Group (Front) – Time
– Gear Group – Inspect
– General Information
– Glossary of Electronic Control Terms
– Glow Plugs – Test
– Lubrication System
– Main Bearings – Inspect
– Piston Height – Inspect
– Piston Ring Groove – Inspect
– Turbocharger – Inspect
– Valve Depth – Inspect
– Valve Guide – Inspect
– Water Pump – Inspect
– Water Temperature Regulator – Test
Troubleshooting C1.7 and C2.2 Industrial Engine
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem – Charging Problem and/or Noisy
– Battery Problem
– Belt Tensioner Noise
– CAN Data Link – Test
– Codes that Inhibit Operation of Aftertreatment System
– Component Location
– Configuration Parameters
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Coolant Temperature Is Low
– Customer Passwords
– Cylinder Is Noisy
– Data Link Configuration Status – Test
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– Diesel Oxidation Catalyst Has Incorrect Inlet Temperature
– Diesel Oxidation Catalyst Has Low Conversion Efficiency
– Diesel Particulate Filter Collects Excessive Soot
– Diesel Particulate Filter Has Low Inlet Pressure
– Diesel Particulate Filter Regeneration
– Diesel Particulate Filter Temperature Is Low
– ECM – Replace
– ECM Software – Install
– ECM Will Not Accept Factory Passwords
– Electrical Connectors – Inspect
– Electrical Power Supply – Test
– Electronic Service Tool Does Not Communicate
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Engine Misfires, Runs Rough or Is Unstable
– Engine Monitoring System
– Engine Overspeeds
– Engine Shutdown Occurs Intermittently
– Engine Speed – Test
– Engine Stalls at Low RPM
– Engine Top Speed Is Not Obtained
– Engine Vibration Is Excessive
– Exhaust Has Excessive Black Smoke
– Exhaust Has Excessive White Smoke
– Exhaust System Contains Coolant
– Exhaust System Contains Oil
– Exhaust Temperature Is High
– Factory Passwords
– Fuel Consumption Is Excessive
– Fuel Contains Water
– Fuel Control – Test
– Fuel Rail Pressure Problem
– Fuel Temperature Is High
– Fuel Transfer Pump – Test
– General Information
– Glow Plug Starting Aid – Test
– Idle Validation – Test
– Indicator Lamp – Test
– Injector Code – Calibrate
– Injector Data Incorrect – Test
– Injector Solenoid – Test
– Inlet Air Is Restricted
– Intake Manifold Air Pressure Is High
– Intake Manifold Air Pressure Is Low
– Intake Manifold Air Temperature Is High
– Mode Selection – Test
– Motorized Valve – Test
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Oil Contains Fuel
– Oil Level Is Low
– Oil Pressure Is Low
– Power Is Intermittently Low or Power Cutout Is Intermittent
– SCR Warning System Problem
– Sensor (Data Link Type) – Test
– Sensor Calibration Required – Test
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Service Tool Error Identifiers
– Service Tool Features
– Speed Control (Analog) – Test
– Speed Control (PWM) – Test
– Speed/Timing – Test
– Switch Circuits – Test – Air Filter Restriction Switch
– Switch Circuits – Test – Engine Oil Pressure Switch
– Switch Circuits – Test – Multiposition Throttle Switch
– System Overview
– Test ECM Mode
– Valve Lash Is Excessive
– Valve Position – Test
– Water in Fuel – Test
– Welding Precaution