236D3 CATERPILLAR SKID STEER LOADER SERVICE REPAIR MANUAL KXL

The 236D3 CATERPILLAR SKID STEER LOADER SERVICE REPAIR MANUAL KXL provides preventive maintenance information and detailed repair and adjustment procedures for skid steer loaders from Caterpillar. This manual helps ensure optimal performance and long service life by covering essential components and operations.

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Media Number -M0097942-00 Publication Date -01/07/2013
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -08/11/2019
i 05366406
Disassembly and Assembly
253D3, 279D3, 289D3 Compact Track Loaders and 257D3 Multi Terrain Loader and 236D3,
242D3, 246D and 262D3 Skid Steer Loaders Engine Supplement
Removal Procedure
Air Cleaner - Remove and Install
SMCS - 1051-010
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to
cool.
Illustration 1 g02794016

3. 3.Remove cover (5).
2.Disconnect hose (3) and harness assembly (4).
1.Open door assembly (1). Raise radiator and hydraulic oil cooler (2).
Illustration 2
Illustration 3
g02794050
g02794054

4. Illustration 4
Illustration 5
g02794056
g03396886
1.
4.Remove filter element (6) and filter element (9).
5.Remove bolts (7) and air cleaner housing (8).
Install air cleaner housing (8) in the reverse order of removal.
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
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Wed Dec 28 09:30:46 UTC+0530 2022

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Media Number -UENR3278-09 Publication Date -01/09/2014
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -19/03/2019
i 05305971
Disassembly and Assembly
C3.3B Engines for Caterpillar Built Machines
Assembly Procedure
Diesel Particulate Filter - Assemble
A
Tool
SMCS - 108F-016
Table 1
Required Tools
Part NumberPart DescriptionQty
Locktite
- Nickel Anti Seize 1
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.
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
NOTICE

6. DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
Note: After cleaning filter assembly or installing a new filter assembly, the Ash Service must be
performed. Refer to Troubleshooting, UENR3423, "Cat ET Service Features - DPF Soot Load Reset".
Note: When installing a new DOC or DPF, Caterpillar recommends documenting the new component
serial numbers on-line. Go to SIS Web and select "View More" under Additional Service Information.
Select the "C3.3B and C3.8 Downloads" link. The new DOC or DPF serial numbers can be entered
through the "C3.3B and C3.8 DPF / DOC Service Info Registration".
Illustration 1
Illustration 2
g03337342
g03337375

7. Illustration 3 g03337490
1.Apply Tooling (A) onto the threads of temperature sensor (3). Install gasket (12) and
temperature sensor (3) onto catalyst assembly (11). Tighten temperature sensor (3) to a torque
of 30 ± 5 N·m (22 ± 3 lb ft).
2.Apply Tooling (A) onto the threads of temperature sensor (2). Install collar (10), gasket (12),
and temperature sensor (2) onto catalyst assembly (11). Tighten temperature sensor (2) to a
torque of 30 ± 5 N·m (22 ± 3 lb ft)
3.Install DPF filter assembly (9) in the correct orientation for the exhaust flow as indicated by the
arrow. Install bolts (7). Install gasket (12). Tighten bolts (7) to a torque of 49 to 64 N·m
(36 to 47 lb ft).
4.Install body assembly (8). Install bolts (6). Tighten bolts (6) to a torque of 49 to 64 N·m
(36 to 47 lb ft).
5.Apply Tooling (A) onto the threads of tube assemblies (4) and temperature sensor (1). Install
temperature sensor (1) onto body assembly (8). Install tube assemblies (4) and pressure sensor
(5). Tighten temperature sensor (1) to a torque of 30 ± 5 N·m (22 ± 3 lb ft). Tighten tube
assemblies (4) to a torque of 19 ± 3 N·m (168 ± 27 lb in).
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:29:43 UTC+0530 2022

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Media Number -UENR3278-09 Publication Date -01/09/2014
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -19/03/2019
i 05305970
Disassembly and Assembly
C3.3B Engines for Caterpillar Built Machines
Disassembly Procedure
Diesel Particulate Filter - Disassemble
SMCS - 108F-015
1.Mark the position of components for installation purposes.
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.
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
NOTICE

9. Illustration 1
Illustration 2
g03337342
g03337375
2.Remove temperature sensor (1) from body assembly (8). Remove tube assemblies (4) and
pressure sensor (5).
3.Remove bolts (6). Remove body assembly (8) and gasket (12).
4.Remove bolts (7) to separate DPF filter assembly (9) from collar (10). Remove DPF filter
assembly (9).
5.Remove temperature sensor (2) from collar (10). Remove collar (10) and gasket (12).
6.Remove temperature sensor (3) from catalyst assembly (11). Remove catalyst assembly (11)
and gasket (12).
7.Clean the Diesel Particulate Filter (DPF). Refer to Special Instruction, REHS7788, "Cleaning
the Diesel Particulate Filter (DPF) on C3.3B and C3.8 Engines".
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:29:36 UTC+0530 2022

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Media Number -UENR3278-09 Publication Date -01/09/2014
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -19/03/2019
i 05218929
Disassembly and Assembly
C3.3B Engines for Caterpillar Built Machines
Removal Procedure
Diesel Particulate Filter - Remove and Install
SMCS - 108F-010
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.

11. NOTICE
1.Disconnect harness assemblies (1).
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
2.Remove bolts (2) and bolts (3). Disconnect harness assembly (4) from pressure sensor.
Illustration 1
Illustration 2
g03337191
g03337204

12. Illustration 3
Illustration 4
Illustration 5
g03337243
g03337246
g03337226
3.Remove bolts (5) from DPF mount bracket.
4.Use two people to remove diesel particulate filter (6).
5.Remove temperature sensors (7). Remove pressure sensor (8) and tube assemblies (9).

13. Installation Procedure
1.
Install diesel particulate filter (6) in the reverse order of removal.
a.Tighten bolts (5) to a torque of 52 ± 3 N·m (38 ± 2 lb ft).
b.Tighten sensors (7) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
c.Tighten tube assemblies (9) to a torque of 19 ± 3 N·m (168 ± 27 lb in).
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:29:57 UTC+0530 2022

14. Previous Screen
Shutdown SIS
Media Number -M0097942-00 Publication Date -01/07/2013
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -08/11/2019
i 07731298
Disassembly and Assembly
253D3, 279D3, 289D3 Compact Track Loaders and 257D3 Multi Terrain Loader and 236D3,
242D3, 246D and 262D3 Skid Steer Loaders Engine Supplement
Removal Procedure
Diesel Particulate Filter - Remove and Install
SMCS - 108F-010; 108F
S/N - CW91-UP
S/N - GK61-UP
S/N - HSX1-UP
S/N - KEZ1-UP
S/N - KXL1-UP
S/N - ME61-UP
S/N - S7E1-UP
S/N - TE91-UP
Start By:
a.Remove the engine.

15. 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.
Do not tilt the cab using an open door. The door must be closed and
latched when lifting the cab. The door may become dislodged from its
hinges and may cause serious personal injury or death.
Do not go beneath cab unless cab is empty and support lever is engaged.
Failure to follow the instructions or heed the warnings could result in
injury or death.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
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.

16. NOTICE
1.Remove exhaust pipe assembly (1). Disconnect harness assemblies (2).
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
Illustration 1
Illustration 2
g03379477
g03392179

17. Illustration 3
Illustration 4
Illustration 5
g03392196
g03349582
g03349570
3.Remove nuts (6).
2.Loosen bolt (3). Attach a suitable lifting device to implement valve (5). Remove bolts (4).
Relocate implement valve (5).

18. 6.Remove bracket (15). Relocate hydraulic tank (16) forward.
5.Loosen jam nuts (12). Disconnect cable assembly (13). Disconnect hose assembly (14).
4.Disconnect hose assemblies (7). Disconnect harness assemblies (8). Disconnect harness
assemblies (9). Disconnect hose assemblies (10). Remove bolts (11).
Illustration 6
Illustration 7
g03349644
g03392218

19. Illustration 8
Illustration 9
Illustration 10 g03349748
g03392234
g03349691
1.
7.Remove fitting (17).
Install diesel particulate filter (22) in the reverse order of removal.
a.Tighten bolts (21) to a torque of 52 ± 3 N·m (38 ± 2 lb ft).
9.Remove bolts (21).
10.Use suitable lifting device to remove diesel particulate filter (22). The weight of diesel
particulate filter (22) is approximately 32 kg (70 lb).
8.Remove bolt (18). Repeat for opposite side. Remove bolt (20) not shown. Repeat for opposite
side. Remove cover assembly (19).
Installation Procedure

20. Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:31:08 UTC+0530 2022

21. Previous Screen
Shutdown SIS
Media Number -M0097942-00 Publication Date -01/07/2013
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -08/11/2019
i 07731298
Disassembly and Assembly
253D3, 279D3, 289D3 Compact Track Loaders and 257D3 Multi Terrain Loader and 236D3,
242D3, 246D and 262D3 Skid Steer Loaders Engine Supplement
Removal Procedure
Diesel Particulate Filter - Remove and Install
SMCS - 108F-010; 108F
S/N - CW91-UP
S/N - GK61-UP
S/N - HSX1-UP
S/N - KEZ1-UP
S/N - KXL1-UP
S/N - ME61-UP
S/N - S7E1-UP
S/N - TE91-UP
Start By:
a.Remove the engine.

22. 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.
Do not tilt the cab using an open door. The door must be closed and
latched when lifting the cab. The door may become dislodged from its
hinges and may cause serious personal injury or death.
Do not go beneath cab unless cab is empty and support lever is
engaged. Failure to follow the instructions or heed the warnings could
result in
injury or death.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to
cool.
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.

23. NOTICE
1.Remove exhaust pipe assembly (1). Disconnect harness assemblies (2).
Do not strike any part of the assembly of the Diesel Particulate Filter
(DPF). Do not allow any object to contact the internal element of the
DPF. If the internal element of the DPF becomes damaged, the
assembly must be replaced.
Illustration 1
Illustration 2
g03379477
g03392179

24. Illustration 3
Illustration 4
Illustration 5
g03392196
g03349582
g03349570
3.Remove nuts (6).
2.Loosen bolt (3). Attach a suitable lifting device to implement valve (5). Remove bolts (4).
Relocate implement valve (5).

25. 6.Remove bracket (15). Relocate hydraulic tank (16) forward.
5.Loosen jam nuts (12). Disconnect cable assembly (13). Disconnect hose assembly (14).
4.Disconnect hose assemblies (7). Disconnect harness assemblies (8). Disconnect harness
assemblies (9). Disconnect hose assemblies (10). Remove bolts (11).
Illustration 6
Illustration 7
g03349644
g03392218

26. Illustration 8
Illustration 9
Illustration 10 g03349748
g03392234
g03349691
1.
7.Remove fitting (17).
Install diesel particulate filter (22) in the reverse order of removal.
a.Tighten bolts (21) to a torque of 52 ± 3 N·m (38 ± 2 lb ft).
9.Remove bolts (21).
10.Use suitable lifting device to remove diesel particulate filter (22). The weight of diesel
particulate filter (22) is approximately 32 kg (70 lb).
8.Remove bolt (18). Repeat for opposite side. Remove bolt (20) not shown. Repeat for opposite
side. Remove cover assembly (19).
Installation Procedure

27. Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:29:24 UTC+0530 2022

28. Previous Screen
Shutdown SIS
Media Number -UENR3278-09 Publication Date -01/09/2014
Product: SKID STEER LOADER
Model: 236D3 SKID STEER LOADER KXL
Configuration: 236D3 Skid Steer Loader KXL00001-UP (MACHINE) POWERED BY C3.3B Engine
Date Updated -19/03/2019
i 05305930
Disassembly and Assembly
C3.3B Engines for Caterpillar Built Machines
Removal Procedure
Exhaust Gas Recirculation Valve - Remove and Install
SMCS - 108N-010
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The
radiator and all lines to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to relieve pressure only
when engine is stopped and cooling system pressure cap is cool enough
to touch with your bare hand.
Do not attempt to tighten hose connections when the coolant is hot, the
hose can come off causing burns.
Cooling System Coolant Additive contains alkali. Avoid contact with
skin and eyes.
NOTICE

29. 2.Disconnect hoses (2) and (3). Remove bolts (4).
Note: Refer to Specifications, "Engine Design" for non-specified engine torque values.
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, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1.Drain coolant below exhaust gas recirculation valve level. Remove heat shield (1).
Illustration 1
Illustration 2
g02824663
g03337068

30. Illustration 3
Illustration 4 g03366813
g03366811
1.
Install exhaust gas recirculation valve (5) in the reverse order of removal.
a.Tighten bolts (4) and (11) to a torque of 24 to 27 N·m (212 to 239 lb in).
b.Tighten screws (13) to a torque of 10 to 11 N·m (89 to 97 lb in).
4.Remove screws (13) and reed valve (12) from exhaust gas recirculation valve (5).
3.Disconnect harness assembly (9), hose (6) and (10). Remove bolts (11) and bolts (7). Remove
exhaust gas recirculation valve (5) and cooler assembly (8).
Installation Procedure
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 28 09:32:38 UTC+0530 2022

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