Caterpillar Cat 246 Skid Steer Loader (Prefix 5SZ) Service Repair Manual (5SZ04000 and up).pdf

Service Repair Manual
Models
246 Skid Steer Loader

Shutdown SIS
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Product: SKID STEER LOADER
Model: 246 SKID STEER LOADER 5SZ
Configuration: 236 246 252 262 Skid Steer Loader 5SZ04000-UP (MACHINE) POWERED BY 3034 Engine
Disassembly and Assembly
3034 Engine for Caterpillar Built Machines
Media Number -SENR5013-08 Publication Date -01/11/2008 Date Updated -14/11/2008
i01365306
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
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.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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236 246 252 262 Skid Steer Loader 5SZ04000-UP (MACHINE) POWERED BY 3034...
2019/11/16
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Illustration 1 g00596955
1. Loosen hose clamps (1) and (3). Slide the hoses away from turbocharger (2) .
2. Remove oil line (4) from turbocharger (2). Immediately cap all openings or plug all
openings in order to prevent contamination.
3. Loosen hose clamp (5) for the oil drain line.
4. Remove three nuts (6) that fasten turbocharger (2) to the exhaust manifold.
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5. Remove turbocharger (2) and gasket (7) from the engine. Plug the hose for the oil drain line
in order to prevent contamination. Inspect the condition of gasket (7). If gasket (7) is worn
or damaged, replace the gasket.
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All Rights Reserved.
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Sat Nov 16 00:47:52 UTC+0800 2019
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Shutdown SIS
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i01130095
Turbocharger - Install
SMCS - 1052-012
Installation Procedure
NOTICE
1. Put gasket (7) and turbocharger (2) in position on the exhaust manifold.
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2. Install three nuts (6) that fasten turbocharger (2) to the exhaust manifold. Tighten the nuts to
a torque of 22 N·m (16 lb ft).
3. Tighten hose clamp (5) for the oil drain line.
4. Connect oil line (4) to turbocharger (2) .
5. Slide the hoses toward turbocharger (2) and tighten hose clamps (3) and (1) .
Sat Nov 16 00:48:47 UTC+0800 2019
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Shutdown SIS
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i01099748
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Removal Procedure
NOTICE
1. Remove eight bolts (1) from exhaust manifold (2) .
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2. Remove exhaust manifold (2) and gasket (3) from the engine.
NOTICE
1. Make sure that the cylinder head and the exhaust manifold are clean and free of carbon and
gasket material.
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2. Install two guide bolts (4) into two of the bolt holes for the exhaust manifold bolts. The
guide bolts are used to keep exhaust manifold gasket (3) and exhaust manifold (2) in
position on the cylinder head during installation.
3. Put a new exhaust manifold gasket (3) in position on the engine. It is not necessary to use a
sealer on the exhaust manifold gasket.
4. Put exhaust manifold (2) in position on the engine.
5. Install six of the eight bolts (1) and remove the two guide bolts. Install the remaining two
bolts (1) .
6. Tighten eight bolts (1) in an outward pattern. Begin with the center of the exhaust manifold.
Tighten bolts (1) to a torque of 18 N·m (13 lb ft).
Sat Nov 16 00:49:43 UTC+0800 2019
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Shutdown SIS
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i01333774
Inlet Manifold - Remove
SMCS - 1058-011
Removal Procedure
Start By:
A. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove and Install".
NOTICE
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1. Remove eight bolts (1) from air inlet manifold (2) .
2. Remove air inlet manifold (2) and gasket (3) from the engine. Check the condition of gasket
(3). If gasket (3) is worn or damaged, use a new part for replacement.
Sat Nov 16 00:50:39 UTC+0800 2019
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Shutdown SIS
Previous Screen
i01333848
Inlet Manifold - Install
SMCS - 1058-012
NOTICE
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1. Install two guide bolts (4) into the cylinder head, as shown. The guide bolts are used to keep
gasket (3) and air inlet manifold (2) in position on the cylinder head during installation.
2. Put gasket (3) in position on the engine.
3. Put air inlet manifold (2) in position on the engine.
4. Install six of the eight bolts (1) and remove two guide bolts (4). Install the remaining two
bolts (1) .
5. Tighten bolts (1) to a torque of 22 N·m (16 lb ft).
End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove and Install".
Sat Nov 16 00:51:35 UTC+0800 2019
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Shutdown SIS
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i01458210
Inlet and Exhaust Valve Springs - Remove and Install
SMCS - 1108-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6195 Valve Spring Compressor 1
Start By:
A. Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -
Remove".
NOTICE
Note: Before you begin the removal of the valve springs, refer to the Specifications Module,
"Cylinder Head Valves" topic for appropriate information on the valve springs.
1. Ensure that the piston is at the top center position.
Note: If the rocker arm assembly has not been removed, rotate the crankshaft in the normal
direction of rotation until the inlet valve of the appropriate cylinder has just opened and the
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exhaust valve has not fully closed. If the rocker arm assembly has been removed, go to Step
2.
NOTICE
Do not turn the crankshaft while the valve springs are removed.
a. Install Tool (A) .
b. Compress the valve springs in order to open the valve.
c. Turn the crankshaft until the piston touches the valve.
d. Continue to turn the crankshaft and release the pressure of Tool (A) until the piston is
at the top center position.
2. Install Tool (A) .
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3. Compress valve springs (1). Remove two valve keepers (2) .
NOTICE
Ensure that the valve spring is compressed squarely or damage to the
valve stem may occur.
4. Release the pressure on Tool (A). Remove valve spring retainer (3) and valve springs (1) .
Note: If you are replacing all of the valve springs, the procedure can be done on two
cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on
cylinder 2 and cylinder 3.
NOTICE
Do not turn the crankshaft while the valve springs are removed.
Table 2
Required Tools
NOTICE
1. Place the new valve springs into position.
Note: Ensure that the closed damper coils are toward the cylinder head if double valve
springs are used.
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2. Install valve spring retainer (3) .
3. Install Tool (A). Compress valve springs (1) .
NOTICE
Ensure that the valve spring is compressed squarely or damage to the
valve stem may occur.
4. Install two valve keepers (2) .
5. Release the pressure slowly on Tool (A). Remove Tool (A). Strike the top of the valves with
a soft faced hammer in order to ensure that the valve keepers are properly installed.
Note: If you are replacing all of the valve springs the procedure can be done on two
cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on
cylinder 2 and cylinder 3.
End By: Install the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod
- Install".
Sat Nov 16 00:52:30 UTC+0800 2019
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Shutdown SIS
Previous Screen
i01739737
Inlet and Exhaust Valves - Remove and Install
SMCS - 1105-010
Removal Procedure
Table 1
Required Tools
Start By:
a. Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head -
Remove".
NOTICE
1. Clean the bottom face of the cylinder head. Use a dial indicator to check the depth of the
valves below the face of the cylinder head before the valve springs are removed. Refer to
Specifications, RENR2401, "Cylinder Head Valves" for the correct dimensions.
2. Place an index mark on the heads of the inlet valves and the exhaust valves for installation
purposes.
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3. Use Tooling (A) to compress inner springs (3) and outer springs (4).
Note: Some engines may have only a single inlet valve spring and a single exhaust valve
spring.
4. Remove valve keepers (1).
The valve keepers can be thrown from the valve when the valve spring
compressor is released. Ensure that the valve keepers are properly
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installed on the valve stem. To help prevent personal injury, keep away
from the front of the valve keepers and valve springs during the
installation of the valves.
5. Slowly release the pressure on Tooling (A) and remove Tooling (A).
6. Remove valve spring retainers (2).
7. Remove inner springs (3) and outer springs (4).
8. Remove seals (5).
9. Remove valve spring seat washers (6).
10. Remove inlet valves (7) and exhaust valves (7).
Table 2
Required Tools
NOTICE
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1. Lubricate the stems of inlet valves (7) and the stems of exhaust valves (7) with clean engine
oil.
2. Install inlet valves (7) and exhaust valves (7) in the respective positions.
3. Install valve spring seat washers (6).
4. Install new seals (5).
5. Install inner springs (3) and outer springs (4).
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Note: Install inner springs (3) and outer springs (4) on the valve spring seat washers with
the damper coils toward the cylinder head. This is done with double valve springs. If single
valve springs are used, the springs can be installed in either way.
6. Install valve spring retainers (2).
The valve keepers can be thrown from the valve when the valve spring
compressor is released. Ensure that the valve keepers are properly
installed on the valve stem. To help prevent personal injury, keep away
from the front of the valve keepers and valve springs during the
installation of the valves.
7. Use Tooling (A) to compress inner springs (3) and outer springs (4).
Note: Some engines may have only a single inlet valve spring and a single exhaust valve
spring.
8. Install valve keepers (1).
9. Slowly release the pressure on Tooling (A) and remove Tooling (A). Strike the top of the
valves with a soft hammer in order to ensure that the valve keepers are properly installed.
Note: Refer to Specifications, RENR2401, "Cylinder Head Valves" for more information on
inlet valves and exhaust valves.
10. Use a dial indicator to check the depth of the new valves below the cylinder head. If the
depth of the new valves is below the correct depth, the valve seat inserts must be replaced.
Refer to Disassembly and Assembly, "Inlet and Exhaust Valve Seat Inserts - Remove and
Install".
End By:
a. Install the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head -
Install".
Sat Nov 16 00:53:26 UTC+0800 2019
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Caterpillar Cat 246 Skid Steer Loader (Prefix 5SZ) Service Repair Manual (5SZ04000 and up).pdf

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