901C2 Caterpillar Compact Wheel Loader Service Repair Manual

SERVICE REPAIR MANUAL 901C2 COMPACT WHEEL LOADER

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





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





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





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

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

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

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

 



          



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 



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

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

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 



     



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

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

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

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s

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05242994

Bearing Clearance - Check SMCS - 1203-535; 1219-535

Measurement Procedure Table 1 Required Tools Tool

Part Description

Qty

198-9142

Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)

1

Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)

1

Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)

1

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

1

s 198-9143

A

m a

Part Number

198-9144

198-9145

Note: Refer to Specification UENR0995 "Engine Design" for non-specified engine Torque Values.

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. The checking can result in the possibility of obtaining inaccurate information and the possibility of damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

e l p

NOTICE

Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

m a

The technician must be careful to use Tooling (A) correctly. The following points must be remembered: • Ensure that the backs of the bearings and the bores are clean and dry.

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

s

• The crankshaft must be free of oil at the contact points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1

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Typical Example

g01152855

m a

4. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.

s

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Wed Jul 15 13:59:18 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243607

Camshaft - Remove and Install SMCS - 1210-010

Removal Procedure Table 1 Required Tools

m a

Tool

Part Number

Part Description

Qty

A

-

Magnets

8

Start By:

s

a. Remove the rocker shaft and pushrods. b. Remove the front housing.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1

g02720888

e l p

1. Ensure that Timing Marks (Y) on the idler gear and the camshaft gear are aligned. Refer to illustration 1.

m a

Illustration 2

g02721408

2. Use a magnet to hold up the lifters in order to remove the camshaft.

s

Illustration 3

g02721410

NOTICE Do not damage the lobes or the bearings when the camshaft is removed or installed.

3. Remove bolts (2) and the washers.

4. Carefully remove camshaft (1) from the cylinder block.

Installation Procedure

e l p

1. Install camshaft (1) in the reverse order of removal.

a. Apply engine oil to threads and torque bolts (2) to 24 to 27 N·m (18.0 to 20.0 lb ft).

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Wed Jul 15 13:56:27 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243616

Camshaft Gear - Remove and Install SMCS - 1210-010-GE

Removal Procedure Table 1 Required Tools

m a

Tool

Part Number

A

1P-0510

B

8B-7551

s

Start By:

Part Description

Qty

Driver Group

1

Puller Assembly

1

a. Remove the camshaft.

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.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

e l p

g02721209

m a

1. Use Tooling (A) in order to remove camshaft gear (1) from camshaft (2). Use Tooling (B) in order to install camshaft gear (1) onto camshaft (2).

s

Illustration 2

g02721212

2. Remove plate (3) from camshaft (2).

3. If necessary, remove the key from the nose of the camshaft.

Installation Procedure

1. Install camshaft gear (1) in the reverse order of removal. a. Ensure that the camshaft gear and the key are clean and free from wear and damage.

Copyright 1993 - 2020 Caterpillar Inc.

Wed Jul 15 13:56:40 UTC+0530 2020

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e l p

s

m a

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05399036

Connecting Rod Bearings - Install SMCS - 1219-012

Installation Procedure NOTICE

m a

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

s

NOTICE

Discard all used Connecting Rod fasteners.

1. Ensure that the bearing shells are clean and free from wear and damage. If necessary, replace the bearing shells.

Illustration 1

g02720402

e l p

2. Install upper bearing shell (6) into connecting rod (5) . Ensure that the locating tab for the upper bearing shell is correctly seated in the slot in connecting rod (5) .

Note: The ends of the upper bearing shell must be centered in the connecting rod. The ends of the upper bearing shell are to be positioned equally in relation to the mating faces of the connecting rod.

3. Lubricate upper bearing shell (6) with clean engine oil.

s

m a

Illustration 2

g02720401

4. Carefully pull connecting rod (5) against the crankshaft.

5. Clean connecting rod cap (4) . Install the lower bearing shell into connecting rod cap (4) .

Ensure that the locating tab for the lower bearing shell is correctly seated in the slot in connecting rod cap (4) .

6. Lubricate the crankshaft and lubricate the lower bearing shell with clean engine oil.

7. Install connecting rod cap (4) to the connecting rod.

Note: Ensure that etched Number on connecting rod cap (4) matches etched Number on the connecting rod. Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.

8. Install new bolts (3) to the connecting rod. Apply engine oil to the threads and tighten the bolts evenly to a torque of 41 to 46 N·m (30 to 34 lb ft).

Illustration 3

e l p

g02720399

9. Position engine oil screen (1) and install the O-ring seal and bolt (2) .

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10. Repeat Step 2 through Step 8 for the remaining connecting rod bearings.

Note: If all connecting rod bearings 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 both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.

s

End By: Install the engine oil pan.

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Wed Jul 15 13:58:19 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243649

Connecting Rod Bearings - Remove SMCS - 1219-011

Removal Procedure Start By:

m a

a. Remove the engine oil pan.

NOTICE

Keep all parts clean from contaminants.

s

Contaminants may cause rapid wear and shortened component life.

NOTICE

Discard all used Connecting Rod fasteners.

Note: If all connecting rod bearings 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 3Ensure that both pairs of the connecting rod bearings are installed before changing

from one pair of cylinders to another pair of cylinders. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.

Illustration 1

e l p

g02720399

1. Remove bolt (2), the O-ring seal, and oil pump screen (1).

m a

s

Illustration 2

g02720401

2. The connecting rod and the connecting rod cap should have an etched Number (X) on the side.

The number on the connecting rod and the connecting rod cap must match. If necessary, make a temporary mark on the connecting rod and connecting rod cap (4) in order to identify the cylinder number.

3. Remove bolts (3). Remove connecting rod cap (4) from the connecting rod.

Illustration 3

g02720402

e l p

4. Carefully push connecting rod (5) into the cylinder bore until connecting rod (5) is clear of the crankshaft. Remove upper bearing shell (6) from connecting rod (5). Keep the bearing shells together.

5. Repeat Step 2 through Step 4 for the remaining bearing shells.

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Wed Jul 15 13:58:06 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243665

Coolant Temperature Sensor - Remove and Install SMCS - 1906-010

Removal Procedure NOTICE

m a

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

s

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.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system to a level below the coolant temperature sensor.

Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.

Illustration 1

e l p

g02798196

2. Disconnect harness assembly (2) from coolant temperature sensor (1).

3. Use a deep socket in order to remove coolant temperature sensor (1) from water temperature regulator (3).

Installation Procedure

m a

1. Install coolant temperature sensor (1) in the reverse order of removal. a. Use caution when tighten down harness assembly (2).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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Wed Jul 15 13:59:33 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243515

Crankshaft Front Seal - Install SMCS - 1160-012

Installation Procedure NOTICE

m a

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

s

Note: The crankshaft front seal should be installed dry. Lubricate the inner rubber portion of the crankshaft front seal.

1. Inspect the nose of the crankshaft for damage. Ensure that the crankshaft is clean and dry.

Illustration 1

g02717557

e l p

2. Position a new crankshaft front seal (3). Install crankshaft front seal (3).

m a

Illustration 2

g02717555

3. Lubricate the inner rubber portion of the crankshaft front seal. Position sleeve (2) on the crankshaft and install key (1).

s

End By:

a. Install the crankshaft pulley.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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Wed Jul 15 13:53:47 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243500

Crankshaft Front Seal - Remove SMCS - 1160-011

Removal Procedure Start By:

m a

a. Remove the crankshaft pulley.

NOTICE

Keep all parts clean from contaminants.

s

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.

Dispose of all fluids according to local regulations and mandates.

Illustration 1

e l p

g02717555

1. Remove key (1) and sleeve (2) from the crankshaft.

m a

Illustration 2

s

g02717557

2. Remove crankshaft front seal (3).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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Wed Jul 15 13:53:35 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243662

Crankshaft Gear - Remove and Install SMCS - 1204-010-GE

Removal Procedure Table 1 Required Tools

m a

Tool

Part Number

Part Description

Qty

A

1P-2321

Puller Assembly

1

Start By:

s

a. Remove the idler gear.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g02838617

e l p

1. Remove o-ring (1) and collar (2).

m a

Illustration 2

s

Illustration 3

g02838697

g02838698

2. Use Tooling (A) in order to remove crankshaft gear (3) from crankshaft (4).

3. If necessary, remove key (5) from crankshaft (4).

Note: Do not remove the key from the crankshaft unless the key is damaged.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

e l p

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

2. Install crankshaft gear (2) in the reverse order of the removal.

Note: The crankshaft gear (2) taper needs to face toward the cylinder block when installed.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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m a

Wed Jul 15 13:59:03 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C2 COMPACT WHEEL LOADER YKY Configuration: 901C2 Compact Wheel Loader YKY00001-UP (MACHINE) POWERED BY C1.7 Engine

Disassembly and Assembly C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -UENR0128-11

Publication Date -01/08/2015

Date Updated -09/06/2016

e l p i05243660

Crankshaft Main Bearings - Install SMCS - 1203-012

Installation Procedure Table 1 Required Tools

m a

Tool

Part Number

Part Description

Qty

B

387-1351

Crankshaft Bearing Driver

-

C

129-1967

Multipurpose White Grease

1

s

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Install the main bearings dry when the clearance checks are made.

Note: Install the crankshaft main bearings upper and lower halves, with the bearing tabs fitting into the notch of the crankshaft main bearing cases.

Illustration 1

g02715940

Illustration 2

m a

e l p

g02719957

1. Use Tooling (B) and install crankshaft main bearing (12) into the front of the cylinder block.

Install crankshaft main bearing (12) with the seam on the right or left side of the cylinder block.

Note: When the bearing clearance is checked, and the engine is in an upright position, or on the side. The crankshaft must be supported against the upper halves of the main bearings.

Procedure is done in order to get a correct measurement with Tooling (B). If the crankshaft is not supported, the weight of the crankshaft will cause an incorrect reading. If the engine is not in an upright position or on the side, is not necessary to support the crankshaft.

s

Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts" for complete details concerning the measurement of bearing clearances.

Illustration 3

g02715307

e l p

2. Apply Tooling (C) to crankshaft main bearings (7). Install crankshaft main bearings (7) in the upper and lower halves of crankshaft main bearing cases (11). Install three crankshaft main bearing cases (11).

Note: Be careful not to damage the bearings. Match each lower crankshaft main bearing case and the upper main bearing case in order to ensure installation in the original location. The three crankshaft main bearing cases are marked A-B-C with side markings FLYW and HEEL to face toward the flywheel. The rear crankshaft main bearing case to be installed with the bolt holes facing toward the rear of the cylinder block.

s

m a

Illustration 4

g02715313

This is the sample of the manual Click on the download link for complete Manual

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