247B3 CATERPILLAR MULTI TERRAIN LOADER SERVICE REPAIR MANUAL TSL

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Media Number -UENR0256-00 Publication Date -01/06/2010
Product: MULTI TERRAIN LOADER
Model: 247B3 MULTI TERRAIN LOADER TSL
Configuration: 247B3 Multi Terrain Loader TSL00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -09/06/2010
i 02036664
Disassembly and Assembly
216B3 and 226B3 Skid Steer Loaders and 247B3 Multi Terrain Loader Engine S upp
lem ent
Removal Procedure
Air Cleaner - Remove and Install
SMCS - 1051-010
1.Remove harness assembly (2). Loosen hose clamp (3). Disconnect hose (4) .
Illustration 1 g01048892

Tool
A
Table 1
Required Tools
Part NumberPart Description
5P-3413 Pipe Sealant
Qty
1
2.Remove bolts (5). Rotate bracket (6). Remove air cleaner assembly (7). Remove service
indicator (1) from air cleaner assembly (7) .
1.Apply Tooling (A) to service indicator (1). Install service indicator (1) .
2.Install air cleaner assembly (7) into position. Rotate bracket (6) into position in order to secure
the air cleaner assembly. Install bolts (5) .
3.Connect hose (4) onto the air cleaner assembly. Install hose clamp (3). Torque clamp (3) to 4.5
± .5 N·m (40 ± 4 lb in).
4.Connect harness assembly (2) .
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Nov 9 11:15:10 UTC+0530 2022

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Media Number -KENR6948-10 Publication Date -01/06/2015
i 07360106
C1.1, C1.5 and C2.2 Engines for Caterpillar Built Machines
Removal Procedure
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Start By:
a.If the engine is equipped with a turbocharger, remove the turbocharger. Refer to Disassembly
and Assembly, "Turbocharger - Remove and Install".
Note: The three cylinder and the four cylinder engines have different exhaust manifolds. The removal
procedure is similar for all models.
NOTICE

Illustration 1
Typical example
g01326567
1.Loosen nuts (5) and bolts (6).
Note: To prevent distortion of the exhaust manifold, loosen the outer fasteners first.
2.Remove nuts (5) and bolts (6).
Note: Identify bolts of different lengths so that the bolts can be installed in the correct
positions.
3.Remove exhaust manifold (4) from cylinder head (1). Note the orientation of the exhaust
manifold for installation.
4.Remove gasket (3) from cylinder head (1).
5.If necessary, remove exhaust manifold studs (2) from cylinder head (1).
NOTICE

2.If necessary, install exhaust manifold studs (2) to cylinder head (1).
3.Install a new exhaust manifold gasket (3) to cylinder head (1).
4.Align exhaust manifold (4) with studs (2) and install the exhaust manifold to cylinder head (1).
Note: Ensure that the exhaust manifold is installed in the correct orientation.
5.Install nuts (5) and bolts (6) finger tight.
Note: Ensure that bolts of different lengths are installed in the correct positions.
6.For the C1.1 and C1.5 engines, tighten nuts (5) and bolts (6) to a torque of 10 N·m (89 lb in).
For the C2.2 engine, tighten nuts (5) and bolts (6) to a torque of 25 N·m (18 lb ft).
Note: Tighten the inner bolts first.
End By:
a.If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly
and Assembly, "Turbocharger - Remove and Install".
Note: The three cylinder and the four cylinder engines have different exhaust manifolds. The
installation procedure is similar for all models.
1.Ensure that the mating surfaces of the cylinder head and the exhaust manifold are clean and free
from damage.
Illustration 2
Typical example
g01326567

Wed Nov 9 11:15:28 UTC+0530 2022

Wed Nov 9 11:15:21 UTC+0530 2022

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Media Number -UENR0256-00 Publication Date -01/06/2010
i 02036669
216B3 and 226B3 Skid Steer Loaders and 247B3 Multi Terrain Loader Engine S upp
lem ent
Removal Procedure
Muffler - Remove and Install
SMCS - 1062-010
1.Remove bolts (6). Remove gasket (5) .
2.Remove nuts (3). Loosen nut (1). Remove muffler (2) .

Required Tools
ToolPart Number
A 5P-3931
Table 1
Note: Observe the exhaust elbow's position.
3.Remove exhaust elbow (4) .
Part Description
Anti-Seize Compound
Qty
1
1.Install exhaust elbow (4) .
2.Install muffler (2). Tighten nut (1). Install nuts (3) .
3.Apply Tooling (A) to bolts (6). Install gasket (5). Install bolts (6) .
Wed Nov 9 11:15:39 UTC+0530 2022

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i 02602655
Removal procedure
Turbocharger - Remove and Install
SMCS - 1052-010
Note: Plug and cap all open ports and tube assemblies.
Care must be taken to ensure that fluids 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.
NOTICE
NOTICE

1.Loosen hose clamps (5) and remove air inlet hose (1).
2.Remove allen head screws (21) and remove exhaust elbow (19) from turbocharger (4). Remove
gasket (18) from the turbocharger.
3.Remove banjo bolt (2) and washers (3). Remove the fasteners and the spacers (not shown) for
tube clips (6). Remove bolts (14) and remove tube assembly (13) from the cylinder block.
Remove O-ring seal (12).
4.Remove bolts (8) and disconnect tube assembly (10) from the turbocharger. Remove joint (7).
If necessary, remove bolts (9) and remove tube assembly (10) from the cylinder block. Remove
joint (11).
5.Remove nuts (17) and remove turbocharger (4) from the exhaust manifold. Remove gasket (20)
from the exhaust manifold. If necessary, remove studs (15) from the exhaust manifold.
Note: Do not use the actuator rod of the wastegate to lift the turbocharger.
Installation procedure

NOTICE
1.Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear.
If the turbocharger is worn, the complete turbocharger must be replaced.
2.Test the actuator for correct operation. Refer to Systems Operation, Testing and Adjusting,
"Wastegate - Test" for more information. If the actuator is damaged or the actuator does not
operate within the specified limits, the complete turbocharger must be replaced.

Illustration 3
Illustration 4
g01304121
g01304528
3.Clean the mating surfaces of the exhaust manifold. If necessary, install studs (15) to the exhaust
manifold. Tighten the studs to a torque of 18 N·m (13 lb ft). Install a new gasket (20) over the
studs.
4.Position turbocharger (4) onto the exhaust manifold. Install nuts (17) and tighten to a torque of
25 N·m (18 lb ft).
Note: Do not use the actuator rod of the wastegate to lift the turbocharger .
5.Ensure that tube assemblies (10) and (13) are clean and free from damage. If necessary, replace
the tube assemblies.
6.If necessary, position a new joint (11) and tube assembly (10) onto the cylinder block. Install
bolts (9). Tighten the bolts finger tight.
Position a new joint (7) on tube assembly (10). Align tube assembly (10) to the bottom of the
turbocharger. Install bolts (8). Tighten the bolts finger tight.

Tighten bolts (8) and (9) to a torque of 10 N·m (89 lb in).
7.Lubricate the bearings of turbocharger (4) with clean engine oil through oil inlet port (16).
Rotate the shaft of the turbocharger in order to distribute the lubricant.
8.Install a new O-ring seal (12) to tube assembly (13). Position tube assembly (13) against the
cylinder block. Install bolts (14). Tighten the bolts to a torque of 10 N·m (89 lb in).
9.Install new washers (3) and banjo bolt (2) to tube assembly (13). Position tube assembly (13)
onto turbocharger (4). Tighten the banjo bolt finger tight.
10.If necessary, install the spacer and install the fasteners (not shown) to tube clips (6). Torque the
fasteners to 10 N·m (89 lb in).
11.Tighten banjo bolt (2) to a torque of 18 N·m (13 lb ft).
Note: Ensure that the tube assembly does not come into contact with any other components.
12.Clean the mating surfaces of exhaust elbow (19). Position a new gasket (18) and exhaust elbow
(19) on turbocharger (4). Install allen head screws (21). Tighten the bolts to a torque of 32 N·m
(24 lb ft).
13.Ensure that inlet hose (1) is clean and free from defects or restrictions. Loosely install hose
clamps (5) to air inlet hose (1). Install the air inlet hose to the connection of the inlet manifold
(not shown) and to the turbocharger. Tighten the hose clamps.
Wed Nov 9 11:15:47 UTC+0530 2022

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i 08429339
Systems Operation
Air Inlet and Exhaust System
SMCS - 1050
Naturally aspirated engines pull outside air through an air cleaner directly into the inlet manifold. The
air flows from the inlet manifold to the engine cylinders. The fuel is mixed with the air in the engine
cylinders. After the fuel combustion occurs in the engine cylinder, the exhaust gases flow directly to
the outside air through the exhaust manifold and the exhaust system.
Turbocharged engines pull outside air through an air cleaner into the air intake of the turbocharger.
The suction is caused by the turbocharger compressor wheel. Then, the turbocharger compressor
wheel compresses the air. The air flows through the inlet manifold which directs an even distribution
of the air to each engine cylinder. Air is pulled into the engine cylinder during the intake stroke of the
piston. Then, the air is mixed with fuel from the fuel injection nozzles.
Each piston makes four strokes:
1.Intake
Air is drawn into the cylinder through the open inlet valve.
2.Compression
On the compression stroke, the piston moves back up the cylinder and the inlet valves close.
The cool air is compressed further. This additional compression generates more heat.
3.Power
Fuel is sprayed into the engine by the fuel injection nozzle. The mixture of air and fuel ignites
at the top of the compression stroke. The expansion of gases from the combustion forces the
piston downward. This force creates the power of the engine.
4.Exhaust

The piston moves upward to force the gases of combustion from the cylinder through the open
exhaust valve.
The sequence of the strokes by all the pistons in all the engine cylinders provides constant air flow
from the air inlet system during the engine operation.
A turbocharger increases the temperature and the density of the air that is sent to the engine cylinder.
This condition causes a lower temperature of ignition to develop earlier in the compression stroke.
The compression stroke is also timed in a more accurate way with the fuel injection. Surplus air
lowers the temperature of combustion. This surplus air also provides internal cooling.
A turbocharger improves the following aspects of engine performance:
•Power output is increased.
•Engine torque is increased.
•Engine efficiency is increased.
Turbocharger

Components of a turbocharger (typical example)
(1) Air intake
(2) Compressor housing
(3) Compressor wheel
(4) Bearing
(5) Oil inlet port
(6) Bearing
(7) Turbine housing
(8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
A turbocharger is installed between the exhaust and intake manifolds. The turbocharger is driven by
exhaust gases which flow through the exhaust inlet (11). The energy of the exhaust gas turns the
turbine wheel (8). Then, the exhaust gas flows out of the turbine housing (7) through the exhaust
outlet (9).
Turbine wheel (8) and compressor wheel (3) are installed on the same shaft. Therefore, turbine wheel
(8) and compressor wheel (3) rotate at the same rpm. The compressor wheel is enclosed by
compressor housing (2). The compressor wheel compresses the intake air. The intake air flows into
the engine cylinders through the inlet valves of the cylinders.
The oil from the main gallery of the cylinder block flows through the oil inlet port (5) to lubricate the
turbocharger bearings (4) and (6). The pressurized oil passes through the bearing housing of the
turbocharger. The oil is returned through the oil outlet port (10) to the oil pan.
The turbocharger has a wastegate. The wastegate is controlled by the boost pressure. This allows
some of the exhaust gases to bypass the turbine wheel at higher engine speeds. The wastegate is a
type of flapper valve that automatically opens at a preset level of boost pressure to allow exhaust gas
to flow around the turbine. The wastegate allows the design of the turbocharger to be more effective
at lower engine speeds.
Cylinder Head And Valves

Illustration 2g00905459 Cross section of the inlet and exhaust valves in the cylinder head
(typical example)

Illustration 3
Cylinder head and valves (typical example)
(1) Collets
(2) Valve spring retainer
(3) Valve spring
(4) Valve seal
(5) Valve guide
(6) Cylinder head
(7) Cylinder head gasket
(8) Pushrod
(9) Lifter
(10) Exhaust valve
(11) Inlet valve
g00905464
The valves and the rocker shaft assembly control the flow of air into the cylinders and out of the
cylinders during engine operation. The cylinder head assembly has two valves for each cylinder. Each
valve has one valve spring (3). The ports for inlet valve (11) and exhaust valve (10) are on the left
side of the cylinder head.
The valve moves along a steel valve guide (5).
The inlet valve and the exhaust valve are opened and closed by the rotation and movement of the
following components:

•Crankshaft
•Idler gear
•Camshaft
•Valve lifters
•Pushrods
•Rocker arms
•Valve springs
The camshaft gear is driven by the idler gear. The camshaft gear, the idler gear, and the crankshaft
gear are timed together. When the camshaft turns, the valve lifters are moved up and down. The
pushrods move the rocker arms. The rocker arms make the inlet valves and the exhaust valves open
and close. This is in sequence with the firing order of the engine. The valve springs force the valves
back to the closed position.
The valve mechanism cover contains a closed crankcase breather assembly. The gases in the valve
cover, which are caused by blowby, pass from the crankcase to the inlet manifold. The breather is
sealed from the outside air by a diaphragm. Above the diaphragm, the cover is vented to the outside
air by a small vent hole so that pressure does not build up.
Crankcase Breather
Wed Nov 9 11:14:33 UTC+0530 2022

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i 01592413
Testing and Adjusting
Air Inlet and Exhaust System - Inspect
Making contact with a running engine can cause burns from hot parts
and can cause injury from rotating parts.
When working on an engine that is running, avoid contact with hot
parts and rotating parts.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
1.Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not
blocked or collapsed.
SMCS - 1050-040
A general visual inspection should be made to the air inlet and exhaust system. Make sure that there
are no signs of leaks in the system.
There will be a reduction in the performance of the engine if there is a restriction in the air inlet
system or the exhaust system.

2.Inspect the engine air cleaner element. Replace a dirty engine air cleaner element with a clean
engine air cleaner element.
3.Check for dirt tracks on the clean side of the engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the engine air cleaner element and/or the seal for the
engine air cleaner element.
4.For engines with plastic valve mechanism covers, if you experience excessive crankcase
pressure, remove the valve mechanism cover and check the end of the shroud for a skin of
plastic. If the end of the shroud has a skin of plastic, remove the skin of plastic. Ensure that all
of the debris is removed.
5.If the breather tube is made of plastic, use low pressure air to check for a blockage in the
breather tube. If a blockage is inside of the connector, the cover assembly must be replaced. A
broken valve mechanism cover will result if you try to remove the connection.
Wed Nov 9 11:14:46 UTC+0530 2022

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Media Number -KENR6947-08
Publication Date -01/06/2015
i 02282179
Wed Nov 9 11:15:02 UTC+0530 2022
Exhaust Temperature - Test
Measure the Exhaust Temperature
SMCS - 1088-081
Table 1
Required Tools
Part NumberPart NameQty
164-3310 Laser Infrared Thermometer 1
When the engine runs at low idle, the temperature of an exhaust manifold port can indicate the
condition of a fuel injection nozzle.
A low temperature indicates that no fuel is flowing to the cylinder. An inoperative fuel injection
nozzle or a problem with the fuel injection pump could cause this low temperature.
A very high temperature can indicate that too much fuel is flowing to the cylinder. A malfunctioning
fuel injection nozzle could cause this very high temperature.
Use the 164-3310 Laser Infrared Thermometer to check this exhaust temperature at the exhaust outlet
for each cylinder.
Compare the temperature readings for each exhaust outlet. Investigate any difference in the
temperature readings.

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i 02590483
Wastegate - Test
Inspection of the Wastegate
SMCS - 1057-081
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
Note: The turbocharger is a nonserviceable item. The pressure for the wastegate can be checked but
not adjusted.
Before the wastegate is tested, be sure that the inlet air restriction is within the specifications for your
engine. Be sure that the exhaust system restriction is within the specifications for your engine. Refer
to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
The wastegate controls the amount of exhaust gas that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the turbocharger.
When the engine operates in conditions of low boost, a spring presses against a diaphragm in the
canister. The actuating rod will move and the wastegate will close. Then, the turbocharger can operate
at maximum performance.
When the boost pressure increases against the diaphragm in the canister, the wastegate will open. The
rpm of the turbocharger becomes limited. The rpm is limited because a portion of the exhaust gases
bypass the turbine wheel of the turbocharger.

The following levels of boost pressure indicate a problem with the wastegate:
•Too high in full load conditions
•Too low in all low boost conditions
The boost pressure controls the maximum rpm of the turbocharger, because the boost pressure
controls the position of the wastegate. The following factors also affect the maximum rpm of the
turbocharger:
•The engine rating
•The horsepower demand on the engine
•The high idle rpm
•Inlet air restriction
•Exhaust system restriction
1.Remove the heat shield from the turbocharger. Remove the guard for the wastegate.
2.Remove the boost line from the wastegate. Connect an air supply to the wastegate that can be
adjusted accurately.
3.Fasten a suitable dial gauge to the turbocharger so that the end of the actuator rod is in contact
with the plunger of the dial gauge. This will measure axial movement of the actuator rod.
4.Slowly apply air pressure to the wastegate so that the actuator rod moves 1.0 mm (0.039 inch).
The air pressure should be approximately 52 kPa (7.5421 psi). Ensure that the dial gauge
returns to zero when the air pressure is released. Repeat the test several times. This will ensure
that an accurate reading is obtained.
5.Consult your nearest approved Caterpillar dealer or your nearest approved Caterpillar
distributor if the operation of the wastegate is not correct.
Test the Wastegate for Proper Operation
Wed Nov 9 11:14:55 UTC+0530 2022

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i 02237832
Measurement Procedure
Bearing Clearance - Check
A
Tool
SMCS - 1203-535; 1219-535
Table 1
Required Tools
Part NumberPart DescriptionQty
Plastic Gauge (Green)
198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastic Gauge (Red)
198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
Plastic Gauge (Yellow)
198-9145 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
NOTICE

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247B3 CATERPILLAR MULTI TERRAIN LOADER SERVICE REPAIR MANUAL TSL

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