Caterpillar Cat 246D Skid Steer Loader (Prefix HMR) Service Repair Manual (HMR00001 and up).pdf

Service Repair Manual
Models
246D Skid Steer Loader

Shutdown SIS
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Product: SKID STEER LOADER
Model: 246D SKID STEER LOADER HMR
Configuration: 246D Skid Steer Loader HMR00001-UP (MACHINE) POWERED BY C3.3B Engine
Disassembly and Assembly
C2.6 and C3.3B Engines for Caterpillar Built Machines
Media Number -UENR0137-11 Publication Date -01/08/2015 Date Updated -12/07/2018
i05242439
Fuel Injection Pump and Governor - Disassemble
SMCS - 1286-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
390-1150 Injection Pump Gear Puller 1
154-6360 Bolt 1
B 8H-0663 Bearing Puller 1
Start By:
a. Remove fuel injection pump and governor.
Illustration 1 g02805638
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246D Skid Steer Loader HMR00001-UP (MACHINE) POWERED BY C3.3B Engine(...
2019/11/11
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1. Inspect fuel injection pump and governor (1).
2. Remove tube (2).
3. Use suitable blocking and position the fuel injection pump and governor. Remove bolts (4)
and remove governor housing assembly (3).
4. Remove two bolts (4B) and remove stop solenoid (4A). Replace o-ring if necessary.
5. Remove and inspect O-ring seal (5) from governor housing assembly (3). If necessary,
replace O-ring seal (5) with new.
6. Remove shaft (6) and spring (7) from governor housing assembly (3). Remove governor
lever (8).
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7. Remove pin (10) from governor lever assembly (12).
8. Remove speed control lever (9) and spring (11) from governor lever assembly (12).
9. Remove spring (13) and remove governor lever assembly (12) with the O-ring seals.
10. Remove governor sleeve (13) and nut (16). Remove governor weights (15).
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11. Remove nut (17) from gear (18).
Note: Nut (17) has reverse threads.
12. Use Tooling (A) to remove gear (18).
13. Remove bolts (19) and retaining plate (20).
14. Remove fuel camshaft (24) from the housing assembly.
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15. Remove screws (21) and retaining plate (22). If necessary, replace key (23) with new.
16. Use a suitable press and Tooling (B) to remove bearing (25) from fuel camshaft (24) and
ring (27).
17. Use a suitable press and Tooling (B) to remove bearing (26) from fuel camshaft (24).
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Shutdown SIS
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i05242445
Fuel Injection Pump and Governor - Assemble
SMCS - 1286-016
Assembly Procedure
Table 1
Required Tools
A
390-1150 Injection Pump Gear Puller 1
154-6360 Bolt 1
B 8H-0663 Bearing Puller 1
Note: Refer to Specification UENR0995 "Engine Design" for non-specified engine Torque
Values.
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1. Use Tooling (B) and a suitable press to install bearings (26) onto fuel camshaft (24).
2. Position ring (27). Use Tooling (B) and a suitable press to install bearings (25) onto fuel
camshaft (24).
3. If necessary, replace key (23) with new. Position retaining plate (22) and install screws (21).
Tighten screws (21) to a torque of 3.9 to 4.2 N·m (34.5 to 37.4 lb in).
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4. Position fuel camshaft (24) in the housing assembly.
5. Position retaining plate (20) and install bolts (19). Tighten bolts (19) to a torque of
10 to 11 N·m (87 to 100 lb in).
6. Install gear (18).
7. Install nut (17) to gear (18).
8. For the C3.3B Tighten nut (17) to a torque of 138 to 156 N·m (102 to 115 lb ft).
9. For the C2.6 Tighten nut (17) to a torque of 93 to 102 N·m (69 to 75 lb ft).
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10. Position governor weights (15) and install nut (16). Tighten nut (16) to a torque of
63 to 72 N·m (47 to 53 lb ft). Install governor sleeve (14).
Note: Apply engine oil to all internal parts of governor.
11. Install O-ring seals on governor lever assembly (13). Position governor lever assembly (13)
into the governor housing and install spring (12).
12. Install spring (11) and speed control lever (9) on governor lever assembly (13).
13. Install pin (10) into governor lever assembly (13).
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14. Position governor lever (8). Install shaft (6) and spring (7) in governor housing assembly
(3).
15. If necessary, replace O-ring seal (5) with new. Install O-ring seal (5) in governor housing
assembly (3).
16. Use a suitable blocking to support the fuel injection pump and governor. Position governor
housing assembly (3) and install bolts (4). Tighten bolts (4) to a torque of 10 to 11 N·m
(87 to 100 lb in).
17. Inspect fuel injection pump and governor (1) for installation.
18. Install tube (2).
End By:
a. Install fuel injection pump and governor.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Mon Nov 11 23:39:45 UTC+0800 2019
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1. If necessary, install studs (10) and remove cover (11).
2. Install the O-ring seal on fuel injection pump and governor (9). Position fuel injection pump
and governor (9) onto the flywheel housing.
3. Install three nuts (8) to fuel injection pump and governor (9). Tighten nuts (8) to a torque of
18 to 20 N·m (159 ± 177 lb in).
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4. Apply engine oil to threads and torque fitting (7) to a torque of 16 to 19 N·m (12 to 14 lb ft).
5. Install engine oil pressure sensor (6) and connect the wiring harness assembly. Tighten the
engine oil pressure sensor (6) to a torque of 15 to 19 N·m (11 to 14 lb ft).
6. Position bracket (3) and install two nuts (4) and two bolts (5).
7. Check the timing marks and install the O-ring seal and oil plug cap (1). Install the O-ring
seal and cover (2) on flywheel housing (3).
End By:
a. Install the fuel injection lines.
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Mon Nov 11 23:40:41 UTC+0800 2019
4/4
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Shutdown SIS
Previous Screen
i05242455
Fuel Injection Pump - Remove and Install
SMCS - 1251-010
Removal Procedure
Table 1
Required Tools
A 390-1150 Injection Pump Gear Puller 1
Start By:
a. Remove fuel injection line.
Values.
1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF position.
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3. Disconnect hose assembly (2) from fuel injection pump (1).
4. Remove sight cover (3) from fuel injection pump (1).
5. Remove the shutoff solenoid and cover (1A). Install Tooling (A) to hold back the governor
control arm and assist removing the spring (5) and nut (4).
6. Disconnect spring (5) and attach a thin wire to spring (5). Remove nut (4). Position the lever
off the stud.
Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
2/5
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7. Remove two nuts (6) and four bolts (7) from fuel injection pump (1). The fuel injection
pump (1) is spring loaded.
8. Carefully remove fuel injection pump (1) from the fuel injection pump housing.
9. Remove gasket shims (8).
10. If necessary, remove studs (9) from the fuel injection pump housing.
11. To secure the spring from falling inside the housing use wire (10).
12. Clean fuel injection pump (1) and the area around the fuel injection pump. Ensure that the
area is free from contamination before beginning installation.
Installation Procedure
NOTICE
Refer to System Operation, Testing and Adjusting, "Cleanliness of
Fuel System Components" for detailed information on the standards of
cleanliness that must be observed during ALL work on the fuel system.
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1. Keep wire (10) secure to the spring to prevent falling into the housing.
2. If necessary, install studs (9) into the fuel injection pump housing.
3. Position new gasket shims (8) onto the fuel injection pump housing.
Note: When you disassemble or replace, make sure that you use the same number of new
gasket shims with the same thickness.
4. Carefully install fuel injection pump (1) into the fuel injection pump housing .
5. Install four new bolts (7) into fuel injection pump (1). Install two nuts (6) into fuel injection
pump (1). Tighten bolts (7) to a torque of 24 to 27 N·m (214 to 240 lb in). Tighten nuts (6)
to a torque of 18 to 20 N·m (159 to 178 lb in).
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6. Position the lever on the stud. Install nut (4) to hold the lever in place. Tighten nut (4) to a
torque of 3 to 4 N·m (26 to 36 lb in).
7. Connect spring (5) with the thin wire.
8. Install sight cover (3).
9. Connect hose assembly (2) to fuel injection pump (1).
10. Turn the fuel supply to the ON position.
11. Turn the battery disconnect switch to the ON position.
12. After replacement of the fuel injection pump, the fuel injection pump must be calibrated.
Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check".
End By:
a. Install fuel injection lines.
Mon Nov 11 23:41:37 UTC+0800 2019
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1. Disconnect hose assembly (2) from turbocharger (1).
2. Remove tube assembly (3) from turbocharger (1).
3. Remove bolt (4) and the four lower bolts. Remove tube assemblies (5) and the gasket and
the O-ring seal.
4. Remove five bolts (7) and housing (8) and the gasket.
5. Remove four nuts (6) and turbocharger (1) and the gasket.
Table 1
Required Tools
A - Loctite C5A 1
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1. If necessary, install new gaskets.
2. Position the gasket and install turbocharger (1) on the exhaust manifold.
3. Position the gasket and install housing (8) on the turbocharger (1) and install three bolts (7)
to align turbocharger (1).
4. Apply Tooling (A) to three nuts (6) and install three nuts (6) on turbocharger (1). Tighten
three nuts (6) and remove three bolts (7) and housing (8).
5. Apply Tooling (A) to one nut (6) and install one nut (6) on turbocharger (1). Tighten one
nut (6).
6. Position the gasket and housing (8). Apply Tooling (A) on bolts (7) and install five bolts (7)
and tighten.
7. Position tube assemblies (5) and the gasket and the O-ring seal and install four lower bolts
and bolt (4). Tighten bolt (4) to a torque of 16.0 ± 19.0 N·m (11.80 ± 14.01 lb ft).
8. Position tube assembly (3) on turbocharger (1) and install the clamps.
9. Connect hose assembly (2) on turbocharger (1).
Mon Nov 11 23:42:32 UTC+0800 2019
4/5
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Shutdown SIS
Previous Screen
i05242491
Inlet and Exhaust Valve Springs - Remove and Install
SMCS - 1108-010
Removal Procedure
Table 1
Required Tools
A
7F-4292 Valve Spring Compressor 1
9U-6144 Adapter 1
Start By:
a. Remove the rocker shaft and push rod.
Values.
Note: The following procedure should be adopted in order to remove the valve springs when the
cylinder head is installed to the engine. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install" for the procedure to remove the valve springs from a cylinder head
that has been removed from the engine.
Note: Ensure that the appropriate piston is at top dead center before the valve spring is removed.
Failure to ensure that the piston is at top dead center may allow the valve to drop into the cylinder
bore.
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
NOTICE
Ensure that the valve spring is compressed squarely or damage to the
valve stem may occur.
2/4
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1. Follow Step 1.a through Step 1.d in order to position the appropriate piston at top dead
center.
a. Install Tooling (A) in position on the cylinder head in order to compress a valve
spring (4) for the appropriate piston.
b. Use Tooling (A) in order to compress valve spring (4) and open the valve slightly.
Note: Do not compress the spring so that valve spring retainer (3) touches the valve
stem seal.
c. Rotate the crankshaft carefully, until the piston touches the valve.
Note: Do not use excessive force to turn the crankshaft. The use of force can result in
bent valve stems.
d. Continue to rotate the crankshaft and gradually release the pressure on Tooling (A)
until the piston is at the top dead center position. The valve is now held in a position
that allows the valve spring to be safely removed.
Note: If all valve springs require replacement, the procedure can be carried out on two
cylinders at the same time. The procedure can be carried out on the following pairs of
cylinders. 1 with 4 and 2 with 3. Ensure that all of the valve springs are installed before
changing from one pair of cylinders to another pair of cylinders.
NOTICE
Do not turn the crankshaft while the valve springs are removed.
2. Remove valve cap (1). Apply sufficient pressure to Tooling (A) in order to allow removal of
valve keepers (2).
Note: Do not compress the spring so that valve spring retainer (3) touches the valve stem
seal.
3. Slowly release pressure on Tooling (A).
4. Remove valve spring retainer (3) and remove valve spring (4).
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5. Remove Tooling (A).
6. Remove valve stem seals (5).
7. Repeat Step 2 through Step 5 in order to remove the remaining valve springs from the
appropriate cylinder.
1. Install the inlet and exhaust valve springs (4) in the reverse order of removal.
a. Install valve springs with the smaller pitch end (6) downward on cylinder head side.
b. Inspect valve springs (4) for damage and for the correct length. Refer to
Specifications, "Cylinder Head Valves " for further information.
Mon Nov 11 23:45:20 UTC+0800 2019
4/4
2019/11/11

Shutdown SIS
Previous Screen
i05242493
Inlet and Exhaust Valves - Remove and Install
SMCS - 1105-010
Removal Procedure
Table 1
Required Tools
A 5S-1330 Valve Spring Compressor 1
Start By:
a. Remove cylinder head.
Values.
1. Clean the bottom mating surface of the cylinder head. Check the depth of the valves below
the face of the cylinder head before the valve springs are removed. Refer to Specifications,
"Cylinder Head Valves" for the correct dimensions.
2. Place a temporary identification mark on the heads of the valves in order to identify the
correct position.
3. Use a suitable lifting device to position the cylinder head with the valve springs upward.
The weight of the cylinder head is approximately 23 kg (51 lb).
1/3
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Caterpillar Cat 246D Skid Steer Loader (Prefix HMR) Service Repair Manual (HMR00001 and up).pdf

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