This 272D3 XE Caterpillar Skid Steer Loader Service Repair Manual GJ2 provides expert repair and maintenance for Caterpillar skid steer loaders. All the information is heavily illustrated with diagrams and images, along with step-by-step instructions. Keep your Caterpillar machinery running smoothly and efficiently with this comprehensive service manual.

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Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 06044057
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
Air Cleaner - Remove and Install
SMCS - 1051-010
1.Disconnect harness assemblies (1). Remove clamp (2) and the hose.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
Illustration 1 g03787166

3. Illustration 2 g03787168
1.
2.Remove bolts (3) and air cleaner housing (4).
Install air cleaner housing (4) in the reverse order of removal.
a.Tighten bolt (3) to a torque of 25 ± 5 N·m (221 ± 44 lb in).
b.Tighten clamp (2) to a torque of 5 ± 1 N·m (44 ± 9 lb in).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
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Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 08468692
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
Start By:
a.Remove radiator.
b.Remove air cooler.
c.Remove hydraulic oil cooler.
d.Remove DEF injector.
1.Disconnect harness assemblies (4). Remove bolts (1) and reposition sensors (2).
Illustration 1 g03874018

5. 3.Disconnect harness assembly (6) for the Pre NOx sensor, Post NOx Sensor, and SCR Inlet
Temperature Sensor.
Note: The two NOx sensors have different color coded cables. The outlet NOx temperature
sensor is gray and the inlet NOx sensor is black. Mark harness assemblies (4) to ensure that
they are installed to the correct NOx sensor during reassembly.
2.Remove bolts (5) and exhaust extension (3).
Illustration 2 g03874275

6. Illustration 4
Illustration 5
g03874500
g03874645
7.Remove bolts (11) and brackets (12).
5.Use a suitable lifting device to remove catalyst assembly (10). The weight of catalyst assembly
(10) is approximately 23 kg (50 lb).
6.Remove bolts (9) and catalyst assembly (10).

7. c.Tighten clamp assembly (14) and clamp assembly (13) to a torque of 15 ± 2 N·m
(133 ± 18 lb in).
d.Tighten bolts (11), bolts (9), bolts (8), and bolts (7) to a torque of 49 - 55 N·m
(36 - 41 lb ft).
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
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Fri Jul 22 09:05:05 UTC+0530 2022

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Media Number -UENR0129-10 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -05/01/2021
i 06031915
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Removal Procedure
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HLM1-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
Start By:
a.Remove the radiator, air cooler, and hydraulic oil cooler.

9. Illustration 1
Illustration 2
Illustration 3
g03782356
g03782358
g03782359
3.Remove bolts (7) and remove exhaust extension (6).
2.Disconnect hose assemblies (4) and disconnect harness assembly (5).
1.Disconnect harness assemblies (2). Remove bolts (1) and reposition sensors (3).

10. Illustration 4
Illustration 5
g03782360
g03782361
1. Install catalyst (SCR) (12) in the reverse order of removal.
5.Remove mounting bolts (11) and remove catalyst (SCR) (12).
4.Disconnect harness assembly (10). Remove clamps (8) and remove tube assembly (9).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:08:08 UTC+0530 2022

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Media Number -UENR0129-10 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -05/01/2021
i 08468692
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Removal Procedure
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
Start By:
a.Remove radiator.
b.Remove air cooler.
c.Remove hydraulic oil cooler.
d.Remove DEF injector.
1.Disconnect harness assemblies (4). Remove bolts (1) and reposition sensors (2).
Illustration 1 g03874018

12. 4.Remove bolts (7) and bolts (8).
3.Disconnect harness assembly (6) for the Pre NOx sensor, Post NOx Sensor, and SCR Inlet
Temperature Sensor.
Note: The two NOx sensors have different color coded cables. The outlet NOx temperature
sensor is gray and the inlet NOx sensor is black. Mark harness assemblies (4) to ensure that
they are installed to the correct NOx sensor during reassembly.
2.Remove bolts (5) and exhaust extension (3).
Illustration 2
Illustration 3
g03874275
g03874298

13. Illustration 4
Illustration 5
g03874500
g03874645
7.Remove bolts (11) and brackets (12).
5.Use a suitable lifting device to remove catalyst assembly (10). The weight of catalyst assembly
(10) is approximately 23 kg (50 lb).
6.Remove bolts (9) and catalyst assembly (10).

14. Illustration 6
Illustration 7
g03874675
g03874689
8.Remove clamp assembly (14) and pipe assembly (13).
9.Remove bolts (18) and engine lifting eye (17).
10.Remove bolt (19) and bracket (15).
11.Remove bolts (16), bolt (20), bolts (22), and bracket assembly (21).

15. 1.
13.Remove nuts (26), bolt (27), and base bracket (23).
14.Remove bolt (29), bolt (30), nuts (31), and base bracket (28).
Install catalyst assembly (10) in the reverse order of removal.
a.Tighten nuts (31), bolt (30), bolt (29), bolt (27), nuts (26) to a torque of 124 - 147 N·m
(91 - 108 lb ft).
b.Tighten bolts (22), bolts (20), bolt (19), bolts (16), and bolts (18) to a torque of
49 - 55 N·m (36 - 41 lb ft).
c.Tighten clamp assembly (14) and clamp assembly (13) to a torque of 15 ± 2 N·m
(133 ± 18 lb in).
d.Tighten bolts (11), bolts (9), bolts (8), and bolts (7) to a torque of 49 - 55 N·m
(36 - 41 lb ft).
Illustration 9 g03875085
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:08:23 UTC+0530 2022

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Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 06031915
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
Start By:
a.Remove the radiator, air cooler, and hydraulic oil cooler.

17. Illustration 1
Illustration 2
Illustration 3
g03782356
g03782358
g03782359
3.Remove bolts (7) and remove exhaust extension (6).
2.Disconnect hose assemblies (4) and disconnect harness assembly (5).
1.Disconnect harness assemblies (2). Remove bolts (1) and reposition sensors (3).

18. Illustration 5 g03782361
1. Install catalyst (SCR) (12) in the reverse order of removal.
5.Remove mounting bolts (11) and remove catalyst (SCR) (12).
4.Disconnect harness assembly (10). Remove clamps (8) and remove tube assembly (9).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:04:56 UTC+0530 2022

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Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 08257567
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
DEF Injector and Mounting - Remove and Install
SMCS - 108I-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
1.Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator - Tilting".

20. Illustration 1 g03782351
1. Install diesel exhaust fluid injector (3) in the reverse order of removal.
2.Disconnect hose assemblies (1) and disconnect harness assembly (2). Loosen clamp (4) and
remove diesel exhaust fluid injector (3).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:05:22 UTC+0530 2022

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Media Number -UENR0129-10 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -05/01/2021
i 06263253
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Removal Procedure
DEF Injector and Mounting - Remove and Install
SMCS - 108I-010
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Ensure that all adjustments and repairs that are carried out to the
Diesel Emission Fluid (DEF) system are performed by authorized
personnel that have the correct training.
Before beginning ANY work on the DEF system, refer to Operation
and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Emission Fluid (DEF) for the
system are contained during performance of inspection, maintenance,
NOTICE
NOTICE
NOTICE

22. 1. Install diesel exhaust fluid infector (3) in the reverse order of removal.
a.Tighten clamp (4) to a torque of 4.0 ± 0.3 N·m (35 ± 3 lb in).
testing, adjusting, and repair of the product. Be prepared to collect the
fluid with suitable containers before opening any compartment or
disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
3.Disconnect hose assemblies (1) and disconnect harness assembly (2). Loosen clamp (4) and
remove diesel exhaust fluid infector (3).
Note: Use caps to plug all hoses after disconnecting the hoses.
1.Ensure that the purge process for the DEF system is completed before turning the battery
disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual,
"Battery Disconnect Switch" for further information.
2.Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator - Tilting".
Illustration 1 g03782351
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:07:40 UTC+0530 2022

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Media Number -UENR0129-10 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -05/01/2021
i 08257567
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Removal Procedure
DEF Injector and Mounting - Remove and Install
SMCS - 108I-010
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HLM1-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
1.Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator - Tilting".

24. Illustration 1 g03782351
1. Install diesel exhaust fluid injector (3) in the reverse order of removal.
2.Disconnect hose assemblies (1) and disconnect harness assembly (2). Loosen clamp (4) and
remove diesel exhaust fluid injector (3).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:07:49 UTC+0530 2022

25. Previous Screen
Shutdown SIS
Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 06263253
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
DEF Injector and Mounting - Remove and Install
SMCS - 108I-010
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Ensure that all adjustments and repairs that are carried out to the
Diesel Emission Fluid (DEF) system are performed by authorized
personnel that have the correct training.
Before beginning ANY work on the DEF system, refer to Operation
and Maintenance Manual, "General Hazard" for safety information.
NOTICE
NOTICE
NOTICE

26. 1. Install diesel exhaust fluid infector (3) in the reverse order of removal.
a.Tighten clamp (4) to a torque of 4.0 ± 0.3 N·m (35 ± 3 lb in).
Care must be taken to ensure that Diesel Emission Fluid (DEF) for the
system are contained during performance of inspection, maintenance,
testing, adjusting, and repair of the product. Be prepared to collect the
fluid with suitable containers before opening any compartment or
disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
3.Disconnect hose assemblies (1) and disconnect harness assembly (2). Loosen clamp (4) and
remove diesel exhaust fluid infector (3).
Note: Use caps to plug all hoses after disconnecting the hoses.
1.Ensure that the purge process for the DEF system is completed before turning the battery
disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual,
"Battery Disconnect Switch" for further information.
2.Tilt the radiator. Refer to Operation and Maintenance Manual, "Radiator - Tilting".
Illustration 1 g03782351
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:05:14 UTC+0530 2022

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Media Number -M0102468-01 Publication Date -01/01/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -17/02/2021
i 07572145
Disassembly and Assembly
279D3, 289D3, 299D3, and 299D3 XE Compact Track Loaders, and 246D3, 262D3, 272D3,
and 272D3 XE Skid Steer Loaders Engine Supplement
Removal Procedure
Diesel Exhaust Fluid Filter - Remove and Install
SMCS - 108K-010-FI
1.Ensure that the purge process for the DEF system is completed before turning the battery
disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual,
"Battery Disconnect Switch" for further information.
Illustration 1 g06363692

28. Illustration 2 g06363703
1.
2.Remove cover (3), cap (2), and filter (1) from position (X).
Install diesel exhaust fluid filter (3) in the reverse order of removal.
a.Tighten cap (2) to a torque of 9 N·m to 11 N·m (80 lb in to 97 lb in).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jul 22 09:05:40 UTC+0530 2022

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Media Number -UENR0129-10 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 272D3 XE SKID STEER LOADER GJ2
Configuration: 272D3 XHP, 272D3 Skid Steer Loader GJ200001-UP (MACHINE) POWERED BY C3.8 Engine
Date Updated -05/01/2021
i 05949572
Disassembly and Assembly
C3.8 Engines for Caterpillar Built Machines
Removal Procedure
Diesel Exhaust Fluid Filter - Remove and Install
SMCS - 108K-010-FI
S/N - AN91-UP
S/N - BX91-UP
S/N - CY91-UP
S/N - DY91-UP
S/N - GJ21-UP
S/N - HLM1-UP
S/N - HX21-UP
S/N - LB31-UP
S/N - XES1-UP
Start By:
a.Remove the diesel exhaust fluid pump.

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