Caterpillar Cat 236 SKID STEER LOADER (Prefix 4YZ) Service Repair Manual (4YZ00001-03999)

Service Repair Manual
Models
Caterpillar Cat 236 SKID

STEER LOADER
236, 246, 248 Skid Steer Loader 4YZ00001-03999 (MACHINE) POWERED BY 3034... 1/5
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Product: SKID STEER LOADER

Model: 236 SKID STEER LOADER 4YZ
Configuration: 236, 246, 248 Skid Steer Loader 4YZ00001-03999 (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
i01368091
Idler Gear - Remove and Install

SMCS - 1206
Removal Procedure
Start By:
A. Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
B. Remove the front cover. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
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.
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2019/10/21
Illustration 1 g00721939
Note: Rotate the crankshaft until the timing marks on the following gears are aligned:
crankshaft gear, camshaft gear, fuel injection pump gear and idler gear (1) .
1. Remove outer washer (3) from the idler gear shaft.
2. Use a suitable puller to remove idler gear (2) .
Note: Do not rotate the crankshaft once the idler gear has been removed. If the crankshaft is
rotated, the number 1 piston must be set to the top center position. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
3. Remove the inner washer from the idler gear shaft (not shown). The inner washer is located
behind the idler gear.
Remove the Idler Gear Shaft

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0074 Slide Hammer Puller Gp 1
B 4C-5651 Threaded Adapter 1
(4) Idler gear shaft
(5) Oil hole
(6) O-ring seal
1. Remove O-ring seal (6) .
2. Thread tool (B) onto tool (A) .
3. Use tool (A) to remove idler gear shaft (4) .
Install the Idler Gear Shaft

Table 2
Required Tools
Tool Part Number Part Description Qty
C Installation Tool 1
D 159-9076 Seal Installer Handle 1
1. Ensure that oil hole (5) is in the up position.
2. Use a soft hammer (8) to start the idler gear shaft into the cylinder block.
3. Use tool (C) and tool (D) to install the idler gear shaft.
4. Drive the idler gear shaft with the installation tool until the installation tool makes contact
with the machined surface of the cylinder block.
Installation Procedure
1. Install O-ring seal (6) .
2. Install the inner washer onto the idler gear shaft.
3. Install idler gear (2) .
Note: Ensure that the timing marks on the crankshaft gear, the camshaft gear, and the fuel
injection pump gear are aligned with the timing marks on the idler gear (1) .
4. Install the outer washer (3) onto the idler gear shaft.
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Housing (Front) - Install".
b. Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Copyright 1993 - 2019 Caterpillar Inc. Mon Oct 21 22:35:31 UTC+0800 2019
All Rights Reserved.
Private Network For SIS Licensees.
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i01354640
Housing (Front) - Remove

SMCS - 1151-011
Removal Procedure
Start By:
A. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".
B. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
C. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump
- Remove".
NOTICE
NOTICE

containing fluids.

1. Disconnect return spring (1) from the throttle lever on the front housing.
Note: It is necessary to get a reference for the maximum fuel setting in order to remove the
front housing. This setting must be taken from the original front housing before the front
housing is removed.
2. Establish a reference for the maximum fuel setting. Refer to the Testing and Adjusting
Module, "Fuel Setting - Adjust" topic for more information.
3. Remove four nuts (3), bolt (2), and plate (4) from the back side of the front housing.
4. Remove bolts (5) from the back side of the front housing.
Note: Mark the location of the bolts for the front housing. The bolts for the front housing
are different lengths and the bolts must be installed in the original location.
5. Remove bolts (6) and two nuts (7) that fasten the front housing to the cylinder block.
6. Remove front housing (8) and the gasket from the cylinder block. Inspect the gasket and the
front housing for damage. If the gasket or the front housing is damaged, use new parts for
replacement.
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i01354651
Housing (Front) - Install

SMCS - 1151-012
NOTICE
1. Make sure that the mating surfaces of the front housing and the cylinder block are clean and
free from damage.
2. Put the gasket and front housing (8) in position on the engine.
Note: The bolts for the front housing are different lengths and the bolts must be installed in
the original location.
3. Install two nuts (7) and bolts (6) that fasten the front housing to the engine.
4. Install bolts (5) in the back side of the front housing.
5. Put plate (4) in position on the engine and install bolt (2) and four nuts (3) .
6. Set the maximum fuel adjustment. Refer to the Testing and Adjusting Module, "Fuel Setting
- Adjust" topic for more information.
7. Connect return spring (1) to the throttle lever on the front housing.
End By:
a. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump -
Install".
b. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
c. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".
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i01150784
Crankcase Breather - Remove and Install

SMCS - 1317-010
Removal Procedure
NOTICE
NOTICE

containing fluids.

1. Loosen bolts (3) and remove breather cover (6) from the valve mechanism cover.
2. Remove the diaphragm and plate (4). Remove spring (5) .
3. Clean vent hole (2) and breather tube (1). Clean cavity (7) for the breather assembly in the
valve mechanism cover.
NOTICE
NOTICE
Make sure that the components of the breather assembly are installed
correctly. Engine damage may occur if the breather assembly is not
working properly.
1. Install a new spring (5) in cavity (7) for the breather assembly.
2. Install a new diaphragm and plate (4) on top of spring (5) .
3. Install breather cover (6) and four bolts (3). Tighten the bolts to a torque of 9 N·m (80 lb
in).
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i01317371
Valve Mechanism Cover - Remove and Install

SMCS - 1107-010
Removal Procedure
NOTICE
NOTICE

containing fluids.

1. Loosen hose clamps (1) and remove breather tube (2) from the engine.
2. Remove three cap nuts (3), the washers and the rubber seals.
3. Remove valve mechanism cover (4) and the gasket from the engine.
NOTICE
1. Check the condition of the gasket and the rubber seals. If the gasket or the rubber seals are
worn or damaged, use new parts for replacement.
2. Put the gasket and valve mechanism cover (4) in position on the engine.
3. Lubricate cap nuts (3) with clean engine oil. Install the rubber seals, the washers and cap
nuts (3) .
Note: Do not overtighten the cap nuts on the valve mechanism cover.
4. Tighten cap nuts (3) to a torque of 11 N·m (8 lb ft).
5. Put breather tube (2) in position on the engine and tighten hose clamps (1) .
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i01318486
Rocker Shaft and Pushrod - Remove

SMCS - 1102-011; 1208-011
Removal Procedure
Start By:
A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
NOTICE

containing fluids.

1. Loosen eight bolts (1) that fasten the brackets for the rocker shaft (4) to the cylinder head.
Begin with the inner bolts and work toward the outer bolts.
2. Loosen four nuts (3). Begin with the inner nuts and work toward the outer nuts.
Note: Rocker shaft brackets (4) contain three plates (2) that include the studs for the valve
mechanism cover. The plates must be installed in the original location in order to install the
valve mechanism cover.
3. Remove bolts (1) and nuts (3) from the brackets for the rocker shaft (4) .
4. Remove rocker shaft assembly (4) from the cylinder head.
Note: Roll pins (5) are installed in the brackets of rocker shaft (4) in order to align rocker
shaft assembly (4) with oil holes (7) in the cylinder head. Oil holes (7) provide lubrication
to rocker shaft assembly (4) .
5. Place an identification mark on each pushrod (6) in order to locate the pushrods for
installation. Remove eight pushrods (6) from the engine.
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i01511617
Rocker Shaft - Disassemble

SMCS - 1102-015
Disassembly Procedure
Start By:
A. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Remove".
NOTICE
NOTICE

containing fluids.

1. Use a screwdriver or a similar tool to remove retaining ring (6) from both ends of the rocker
shaft assembly.
2. Remove rocker lever (5) from the rocker shaft.
3. Remove rocker shaft bracket (4) from the rocker shaft.
4. Remove spacer (3) and spring (2) from the rocker shaft (1) .
Note: Place an identification mark on each of the components for installation.
Note: The rocker shaft bracket (4) on newer engines is a split assembly.
Mon Oct 21 22:41:26 UTC+0800 2019

Caterpillar Cat 236 SKID STEER LOADER (Prefix 4YZ) Service Repair Manual (4YZ00001-03999)

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Service Repair Manual

Caterpillar Cat 236 SKID

Product: SKID STEER LOADER

Disassembly and Assembly

Idler Gear - Remove and Install

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Remove outer washer (3) from the idler gear shaft.

2. Use a suitable puller to remove idler gear (2) .

Remove the Idler Gear Shaft

(4) Idler gear shaft

(5) Oil hole

(6) O-ring seal

1. Remove O-ring seal (6) .

2. Thread tool (B) onto tool (A) .

3. Use tool (A) to remove idler gear shaft (4) .

Install the Idler Gear Shaft

D 159-9076 Seal Installer Handle 1

1. Ensure that oil hole (5) is in the up position.

2. Install the inner washer onto the idler gear shaft.

3. Install idler gear (2) .

Product: SKID STEER LOADER

Disassembly and Assembly

Housing (Front) - Remove

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Product: SKID STEER LOADER

Disassembly and Assembly

Housing (Front) - Install

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

4. Install bolts (5) in the back side of the front housing.

Product: SKID STEER LOADER

Disassembly and Assembly

Crankcase Breather - Remove and Install

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

2. Remove the diaphragm and plate (4). Remove spring (5) .

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

2. Install a new diaphragm and plate (4) on top of spring (5) .

Product: SKID STEER LOADER

Disassembly and Assembly

Valve Mechanism Cover - Remove and Install

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

4. Tighten cap nuts (3) to a torque of 11 N·m (8 lb ft).

Product: SKID STEER LOADER

Disassembly and Assembly

Rocker Shaft and Pushrod - Remove