232D3 CATERPILLAR SKID STEER LOADER SERVICE REPAIR MANUAL HRS

The 232D3 CATERPILLAR SKID STEER LOADER SERVICE REPAIR MANUAL HRS provides in-depth service and maintenance information for Caterpillar Skid Steer Loaders. It includes detailed instructions and illustrations, helping technicians and DIY users to correctly diagnose and repair the skid steer loader.

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Media Number -M0102048-00 Publication Date -01/05/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -08/11/2019
i 06038381
Disassembly and Assembly
239D3 and 249D3 Compact Track Loaders, and 226D3, 232D3 Skid Steer Loaders Engine
Supplement
Removal Procedure
Air Cleaner - Remove and Install
SMCS - 1051-010
1.Refer to Operation and Maintenance Manual, "Radiator Tilting".
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
Illustration 1 g03784700

3. Illustration 2
Illustration 3
Illustration 4
g03784719
g03784764
g03784767
3.Disconnect hose (5).
2.Disconnect harness assembly (1) and (3). Disconnect hose (2). Remove fuse assembly (4) and
set aside.

4. 1.
4.Remove bolts (7). Remove air cleaner assembly (6).
Install air cleaner housing (6) in the reverse order of removal.
a.Tighten bolts (7) to a torque of 25 ± 3 N·m (221 ± 27 lb in).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:23:45 UTC-1200 2022

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Media Number -UENR4528-02 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -28/05/2019
i 06709950
Disassembly and Assembly
C2.2 Engines for Caterpillar Built Machines
Removal Procedure
Clean Emissions Module - Remove and Install
SMCS - 1050-010; 1050; 7279-010; 7279
Wear goggles, gloves, protective clothing, and a National Institute for
Occupational Safety and Health (NIOSH) approved P95 or N95 half-
face respirator when handling a used Diesel Particulate Filter or
Catalytic Converter Muffler. Failure to do so could result in personal
injury.
The muffler, catalytic converter/muffler, and diesel particulate filter will
become extremely hot during engine operation. A hot muffler, catalytic
converter/muffler and diesel particulate filter can cause serious burns.
Allow adequate cooling time before working on or near the muffler,
catalytic converter/muffler and diesel particulate filter.
NOTICE

6. Do not use power tools to disassemble or assemble any part of the
Diesel Oxidation Catalyst (DOC) or the outlet section.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1.Remove catalyst inlet temperature sensor (10) from Diesel Oxidation Catalyst (DOC) (7). Refer
to Disassembly and Assembly, "Temperature Sensor (Catalyst Inlet) - Remove and Install" for
the correct procedure.
NOTICE
Illustration 1
Typical example
g03817928

7. Do not use power tools to disassemble or assemble any part of the
Diesel Oxidation Catalyst (DOC), or the outlet section.
Wear goggles, gloves, protective clothing, and a National Institute for
Occupational Safety and Health (NIOSH) approved P95 or N95 half-
face respirator when handling a used Diesel Particulate Filter or
Catalytic Converter Muffler. Failure to do so could result in personal
injury.
The muffler, catalytic converter/muffler, and diesel particulate filter will
become extremely hot during engine operation. A hot muffler, catalytic
converter/muffler and diesel particulate filter can cause serious burns.
Allow adequate cooling time before working on or near the muffler,
catalytic converter/muffler and diesel particulate filter.
2.Remove exhaust temperature sensor (4) from the DOC. Refer to Disassembly and Assembly,
"Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure.
3.Disconnect exhaust elbow (11) from the DOC. Refer to Disassembly and Assembly, "Exhaust
Elbow - Remove and Install" for the correct procedure.
4.Remove nut (1), nut (3), nut (6), and nut (9).
5.Remove bracket (5), and bracket (8) from the DOC.
6.Use a suitable lifting device to remove the DOC from mounting bracket (2).
Installation Procedure
NOTICE
NOTICE

8. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1.Ensure that all the components of the Diesel Oxidation Catalyst (DOC) are free from wear and
damage. If necessary, replace any component that is worn or damaged.
2.Use a suitable lifting device to lift the DOC. Position the DOC onto mounting bracket (2).
Ensure that the DOC is correctly positioned onto the bolts on the exhaust mounting bracket (2).
3.Connect exhaust elbow (11) to the DOC . Refer to Disassembly and Assembly, "Exhaust Elbow
- Remove and Install" for the correct procedure.
4.Install bracket (5). Refer to Disassembly and Assembly, "Support and Mounting (CEM) -
Remove and Install" for the correct procedure.
5.Install exhaust temperature sensor (4) to the DOC. Refer to Disassembly and Assembly,
"Temperature Sensor (Exhaust) - Remove and Install" for the correct procedure.
Illustration 2
Typical example
g03817933

9. 6.Install catalyst inlet temperature sensor (10) to the DOC. Refer to Disassembly and Assembly,
"Temperature Sensor (Catalyst Inlet) - Remove and Install" for the correct procedure.
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:23:26 UTC-1200 2022

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Media Number -M0102048-00 Publication Date -01/05/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -08/11/2019
i 06051200
Disassembly and Assembly
239D3 and 249D3 Compact Track Loaders, and 226D3, 232D3 Skid Steer Loaders Engine
Supplement
Removal Procedure
Installation Procedure
Diesel Oxidation Catalyst - Remove and Install
1.
Start By:
a.Tilt cab.
SMCS - 1075-010; 1091-010
Install DOC canister (3) in the reverse order of removal.
1.Remove bolts (1). Remove nuts (2). Remove brackets (4). Remove DOC canister (3).
Illustration 1 g03791186

11. Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:22:27 UTC-1200 2022

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Shutdown SIS
Media Number -M0102048-00 Publication Date -01/05/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -08/11/2019
i 06051200
Disassembly and Assembly
239D3 and 249D3 Compact Track Loaders, and 226D3, 232D3 Skid Steer Loaders Engine
Supplement
Removal Procedure
Installation Procedure
Diesel Oxidation Catalyst - Remove and Install
1.
Start By:
a.Tilt cab.
SMCS - 1075-010; 1091-010
Install DOC canister (3) in the reverse order of removal.
1.Remove bolts (1). Remove nuts (2). Remove brackets (4). Remove DOC canister (3).
Illustration 1 g03791186

13. Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:24:18 UTC-1200 2022

14. Previous Screen
Shutdown SIS
Media Number -M0102048-00 Publication Date -01/05/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -08/11/2019
i 06051200
Disassembly and Assembly
239D3 and 249D3 Compact Track Loaders, and 226D3, 232D3 Skid Steer Loaders Engine
Supplement
Removal Procedure
Installation Procedure
Diesel Oxidation Catalyst - Remove and Install
1.
Start By:
a.Tilt cab.
SMCS - 1075-010; 1091-010
Install DOC canister (3) in the reverse order of removal.
1.Remove bolts (1). Remove nuts (2). Remove brackets (4). Remove DOC canister (3).
Illustration 1 g03791186

15. Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:22:06 UTC-1200 2022

16. Previous Screen
Shutdown SIS
Media Number -UENR4528-02 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -28/05/2019
i 06841173
Disassembly and Assembly
C2.2 Engines for Caterpillar Built Machines
Removal Procedure
Exhaust Cooler (NRS) - Remove and Install - 4 Cylinder
Engines
SMCS - 1087; 108C-010
Sulfuric Acid Burn Hazard may cause serious personal injury or death.
The exhaust gas cooler may contain a small amount of sulfuric acid. The
use of fuel with sulfur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid may spill from the
cooler during service of the engine. The sulfuric acid will burn the eyes,
skin and clothing on contact. Always wear the appropriate personal
protective equipment (PPE) that is noted on a material safety data sheet
(MSDS) for sulfuric acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS) for sulfuric acid.
Start By:
a.Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the
correct procedure.
b.Disconnect the air induction hose from the turbocharger. Refer to Disassembly and assembly,
"Turbocharger - Remove" for the correct procedure.

17. Illustration 1
Alternator removed for clarity
g03815985
1.Loosen hose clamp (10) on hose assembly (11). Disconnect hose assembly (11) from exhaust
cooler (NRS) (7).
2.Loosen hose clamp (9) on hose assembly (8). Disconnect hose assembly (8) from exhaust
cooler NRS) (7).
3.Remove bolts (2) and nuts (6) from tube assembly (1).
4.Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR)
valve assembly (3).
5.Remove gasket (4) (not shown) and gasket (5) (not shown).

18. Illustration 2
Typical example
g03816340
6.Remove bolts (12) from exhaust cooler (NRS) assembly (7).
7.Remove gasket (14) (not shown) from between exhaust manifold (13) and exhaust cooler
(NRS) assembly (7).
8.Remove nut (18) from bracket (17). Support exhaust cooler (NRS) assembly (7) as the bolt is
removed.
9.Remove exhaust cooler (NRS) assembly (7).
10.If necessary, remove studs (15) from exhaust cooler (NRS) assembly (7).

19. 11.Plug and cap all open ports on exhaust cooler (NRS) assembly (7).
12.If necessary, remove bolt (16) and remove bracket (17).
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 4C-5598 Anti-Seize Compound 1
1.Check all components for wear and damage. If necessary, replace any components that are
worn or damaged.
Installation Procedure

20. Illustration 3
Typical example
g03816340
2.Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage.
Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and
damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for
the correct inspection procedure.
Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.
3.Clean the gasket surfaces of exhaust cooler (NRS) assembly (7) and exhaust manifold (13).
4.If necessary, install studs (15) to exhaust cooler (NRS) assembly (7).
5.If necessary, position bracket (17) onto exhaust cooler (NRS) assembly (7). Ensure that the
bracket is correctly orientated.

21. 6.Loosely install nut and bolt (18).
7.Remove plug and cap from all open ports of exhaust cooler (NRS) assembly (7)
8.Position exhaust cooler (NRS) assembly (7) onto the cylinder block.
9.Install bolt (16) to bracket (17). Support exhaust cooler (NRS) assembly (7) as bolt (16) is
installed.
10.Position a new gasket (14) (not shown) between exhaust manifold (13) and exhaust cooler
(NRS) assembly (7).
11.Apply Tooling (A) to the threads of bolts (12). Install bolts (12) to exhaust cooler (NRS)
assembly (7) hand tight.
12.Tighten bolts (12) to a torque of 25 N·m (221 lb in).
13.Tighten bolt (16) to a torque of 25 N·m (221 lb in).
14.Tighten locking nut (18) to a torque of 25 N·m (221 lb in). Ensure that bracket (17) is not
strained as the nut is tightened.

22. Illustration 4
Typical example
g03815985
15.Connect hose assembly (11) to exhaust cooler (NRS) (7). Tighten hose clamp (10) securely.
16.Connect hose assembly (8) to exhaust cooler (NRS) (7). Tighten hose clamp (9) securely.
17.Clean the gasket surfaces of tube assembly (1) and exhaust gas recirculation (EGR) valve
assembly (3).
18.Apply Tooling (A) to the threads of bolts (2).
19.Position a new gasket (3) (not shown) and a new gasket (5) (not shown) onto tube assembly (1).
20.Position tube assembly (1) onto exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR)
valve assembly (3).

23. 21.Apply Tooling (A) to the threads of studs (15).
22.Install bolts (2) and nuts (6) to tube assembly (1). Hand tighten the bolts and nuts.
23.Tighten bolts (2) and nuts (6) to a torque of 25 N·m (221 lb in). Ensure that tube assembly (1) is
not strained as the bolts are tightened.
End By:
a.Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change" for the correct procedure.
b.Connect the air induction hose to the turbocharger. Refer to Disassembly and assembly,
"Turbocharger - Install" for the correct procedure.
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 30 13:25:42 UTC-1200 2022

24. Previous Screen
Shutdown SIS
Media Number -UENR4528-02 Publication Date -01/09/2015
Product: SKID STEER LOADER
Model: 232D3 SKID STEER LOADER HRS
Configuration: 232D3 Skid Steer Loader HRS00001-UP (MACHINE) POWERED BY C2.2 Engine
Date Updated -28/05/2019
i 06841173
Disassembly and Assembly
C2.2 Engines for Caterpillar Built Machines
Removal Procedure
Exhaust Cooler (NRS) - Remove and Install - 4 Cylinder
Engines
SMCS - 1087; 108C-010
Sulfuric Acid Burn Hazard may cause serious personal injury or death.
The exhaust gas cooler may contain a small amount of sulfuric acid. The
use of fuel with sulfur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid may spill from the
cooler during service of the engine. The sulfuric acid will burn the eyes,
skin and clothing on contact. Always wear the appropriate personal
protective equipment (PPE) that is noted on a material safety data sheet
(MSDS) for sulfuric acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS) for sulfuric acid.
Start By:
a.Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the
correct procedure.
b.Disconnect the air induction hose from the turbocharger. Refer to Disassembly and assembly,
"Turbocharger - Remove" for the correct procedure.

25. Illustration 1
Alternator removed for clarity
g03815985
1.Loosen hose clamp (10) on hose assembly (11). Disconnect hose assembly (11) from exhaust
cooler (NRS) (7).
2.Loosen hose clamp (9) on hose assembly (8). Disconnect hose assembly (8) from exhaust
cooler NRS) (7).
3.Remove bolts (2) and nuts (6) from tube assembly (1).
4.Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR)
valve assembly (3).
5.Remove gasket (4) (not shown) and gasket (5) (not shown).

26. Illustration 2
Typical example
g03816340
6.Remove bolts (12) from exhaust cooler (NRS) assembly (7).
7.Remove gasket (14) (not shown) from between exhaust manifold (13) and exhaust cooler
(NRS) assembly (7).
8.Remove nut (18) from bracket (17). Support exhaust cooler (NRS) assembly (7) as the bolt is
removed.
9.Remove exhaust cooler (NRS) assembly (7).
10.If necessary, remove studs (15) from exhaust cooler (NRS) assembly (7).

27. 11.Plug and cap all open ports on exhaust cooler (NRS) assembly (7).
12.If necessary, remove bolt (16) and remove bracket (17).
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 4C-5598 Anti-Seize Compound 1
1.Check all components for wear and damage. If necessary, replace any components that are
worn or damaged.
Installation Procedure

28. Illustration 3
Typical example
g03816340
2.Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage.
Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and
damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for
the correct inspection procedure.
Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.
3.Clean the gasket surfaces of exhaust cooler (NRS) assembly (7) and exhaust manifold (13).
4.If necessary, install studs (15) to exhaust cooler (NRS) assembly (7).
5.If necessary, position bracket (17) onto exhaust cooler (NRS) assembly (7). Ensure that the
bracket is correctly orientated.

29. 6.Loosely install nut and bolt (18).
7.Remove plug and cap from all open ports of exhaust cooler (NRS) assembly (7)
8.Position exhaust cooler (NRS) assembly (7) onto the cylinder block.
9.Install bolt (16) to bracket (17). Support exhaust cooler (NRS) assembly (7) as bolt (16) is
installed.
10.Position a new gasket (14) (not shown) between exhaust manifold (13) and exhaust cooler
(NRS) assembly (7).
11.Apply Tooling (A) to the threads of bolts (12). Install bolts (12) to exhaust cooler (NRS)
assembly (7) hand tight.
12.Tighten bolts (12) to a torque of 25 N·m (221 lb in).
13.Tighten bolt (16) to a torque of 25 N·m (221 lb in).
14.Tighten locking nut (18) to a torque of 25 N·m (221 lb in). Ensure that bracket (17) is not
strained as the nut is tightened.

30. Illustration 4
Typical example
g03815985
15.Connect hose assembly (11) to exhaust cooler (NRS) (7). Tighten hose clamp (10) securely.
16.Connect hose assembly (8) to exhaust cooler (NRS) (7). Tighten hose clamp (9) securely.
17.Clean the gasket surfaces of tube assembly (1) and exhaust gas recirculation (EGR) valve
assembly (3).
18.Apply Tooling (A) to the threads of bolts (2).
19.Position a new gasket (3) (not shown) and a new gasket (5) (not shown) onto tube assembly (1).
20.Position tube assembly (1) onto exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR)
valve assembly (3).

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manual, Please click on the above
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