901C Caterpillar Compact Wheel Loader Service Repair Manual

SERVICE REPAIR MANUAL 901C COMPACT WHEEL LOADER

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

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 

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

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Coolant Contains Oil SMCS - 1348-035; 1395-035

Probable Causes • Engine oil cooler

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• Cylinder head • Cylinder block

Recommended Actions Cylinder Head

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1. Check the cylinder head for flatness. Refer to Systems Operation/Testing and Adjusting.

2. Check the mating face of the cylinder head for wear and signs of leakage. If excessive wear is found, replace the cylinder head. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation/Testing and Adjusting.

3. Inspect the cylinder head gasket for damage and any signs of leakage. If necessary, install a new cylinder head gasket. Refer to Disassembly and Assembly.

Cylinder Block

1. Inspect the top face of the cylinder block for wear and signs of leakage. If excessive wear is found, replace the cylinder block. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation/Testing and Adjusting.

2. Install the cylinder head. Refer to Disassembly and Assembly.

3. Fill the cooling system. Refer to the Operation and Maintenance Manual.

4. Check the quality of the engine oil. If necessary, drain the crankcase and refill the crankcase with clean engine oil. Install new engine oil filters. Refer to Operation and Maintenance Manual.

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Coolant Temperature Is High SMCS - 1395-035

Use this procedure in order to troubleshoot high coolant temperature.

Probable Causes

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• Low coolant level and/or coolant leakage

• Water temperature regulator and/or pressure relief valve • Radiator

• Engine cooling fan

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• Water pump

Recommended Actions Coolant

1. Inspect the coolant level. If necessary, add coolant.

2. Check the mixture of antifreeze and water. Refer to Operation and Maintenance Manual.

3. Check the cooling system for leaks. Repair any leaks immediately.

4. Check for air in the cooling system. Refer to Systems Operation/Testing and Adjusting for the correct procedure.

Water Temperature Regulator and/or Pressure Relief Valve 1. Test the cooling system. Refer to Systems Operation/Testing and Adjusting for the correct procedure.

2. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and undamaged.

3. Check operation of the pressure relief valve and/or the water temperature regulator. If necessary, clean the components and/or replace the components.

Radiator 1. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent fins. Check for collapsed hoses and/or other restrictions.

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2. Check the radiator for internal blockage. Refer to Systems Operation/Testing and Adjusting for more information.

Faulty Engine Cooling Fan

1. Check for loose drive belts. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the fan drive belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to Operation and Maintenance Manual.

Water Pump

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1. Inspect the impeller of the coolant pump for damage and/or erosion.

2. Make sure that the drive gear is not loose on the drive shaft of the coolant pump.

3. If necessary, replace the coolant pump. Refer to Disassembly and Assembly for the correct procedure.

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

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Cylinder Is Noisy SMCS - 1223-035

Probable Causes • Low quality fuel

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• Not enough lubrication • Too much valve lash

• Damage to valve train components • Failure of connecting rod bearing

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Recommended Actions Low Quality Fuel

Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel.

Obtain a fuel analysis.

Not Enough Lubrication Check the lubrication in the valve compartment. Check for sufficient lubrication between the injector tappet and the rocker arm buttons. Check for blocked oil passages. Oil passages must be clean. Ensure that the oil passages that send oil to the cylinder heads are clean.

Valve Lash

Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".

Damage to Valve Train Components Remove the valve cover from the suspect cylinder. Check the following items for damage: camshaft, valve rotocoil, valve springs, lifters, pushrods and bridges. Check for valves that do not move freely.

Remove the cylinder head. Inspect the valves. Replace any damaged parts.

Failure of Connecting Rod Bearing Inspect the connecting rod bearings and the bearing surfaces (journals) on the crankshaft. Check the piston pin for excessive wear. Replace any damaged parts.

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Tue Jul 14 16:37:45 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i05360428

Engine Cranks but Does Not Start SMCS - 1000-035; 1450-035

Probable Causes • Air inlet and exhaust system

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• Fuel supply • Combustion

• Fuel shutoff solenoid

Recommended Actions

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Air Inlet and Exhaust System

1. Check the air filter restriction indicator for a plugged filter. If necessary, service the engine.

Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting.

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the engine has been run out of fuel, prime the fuel system. Refer to Operation and Maintenance Manual for the correct procedure.

2. Ensure that there is good, clean fuel in the fuel tank. Refer to Testing and Adjusting, "Fuel Quality - Test". When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if problem started soon after refueling. Replace the fuel in the fuel tank with good, clean fuel if necessary.

3. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines.

If problems are found with the fuel lines, repair the lines and/or replace the lines.

4. Check the fuel tank for foreign objects which may block the fuel supply.

5. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.

6. Check fuel flow after the fuel filters. If the fuel flow is low, replace the fuel filters.

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7. Ensure that the fuel shutoff solenoid operates correctly. Replace the fuel shutoff solenoid if found faulty.

Combustion Check for mechanical problems in the combustion system.

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Tue Jul 14 16:38:00 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i04564879

Engine Does Not Crank SMCS - 1000-035; 1450-035

Probable Causes • Battery cables and/or batteries

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• Starting circuit

• Internal engine problem

Recommended Repairs

Battery Cables and/or Batteries

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1. Inspect the main power switch, battery posts, and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Clean the battery posts and then replace the cables. Tighten any loose connections.

2. Inspect the batteries.

a. Charge the batteries.

b. Load test the batteries. Refer to Systems Operation/Testing and Adjusting.

Starting Circuit

1. Inspect the starting motor and the flywheel ring gear for damage. Test the operation of the starting motor and associated circuit components. Refer to Systems Operation/Testing and Adjusting.

Internal Engine Problem 1. Remove the glow plugs. Refer to Disassembly and Assembly.

2. Attempt to rotate the crankshaft through 360 degrees in both direction. If the crankshaft rotates correctly but fluid is expelled from the hole for the glow plug, investigate the cause of the fluid in the cylinder. Refer to Systems Operation/Testing and Adjusting.

3. If the crankshaft rotates correctly and no fluid is expelled, install the glow plugs. Refer to Disassembly and Assembly.

4. If the engine does not rotate in Step 2, disassemble the engine. Refer to Disassembly and Assembly.

5. Inspect the internal components for the following conditions:

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Seizure Broken components Bent components Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Engine Has Early Wear SMCS - 1000-035; 1200-035

Premature Engine Wear Probable Causes

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• Incorrect engine oil

• Contaminated engine oil • Contaminated inlet air • Contaminated fuel

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• Restriction in a passage for engine oil

Recommended Repairs Engine Oil

Use engine oil that is recommended and change the engine oil at the interval that is recommended by the engine's Operation and Maintenance Manual.

To determine whether the engine oil is contaminated, obtain an analysis of the engine oil.

Contaminated Inlet Air Inspect the engine air cleaner for cleanliness and good condition. Inspect the connections and the gaskets for the air system.

Contaminated Fuel Inspect the fuel filter. Replace the fuel filter, if necessary.

Contaminants in the fuel such as hydrogen sulfide, sulfur, and chlorofluorocarbons can lead to the formation of acids in the crankcase. Obtain a fuel analysis.

Restriction in a Passage for Engine Oil When some components of the engine show bearing wear in a short time, the cause can be a restriction in a passage for engine oil.

An indicator for the engine oil pressure may indicate sufficient pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for the engine oil supply to the component.

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Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

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Tue Jul 14 16:38:28 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i02785818

Engine Has Mechanical Noise (Knock) SMCS - 1000-035

Probable Causes • Accessory equipment

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• Valve train components • Pistons • Crankshaft • Gear train

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Recommended Actions Accessory Equipment

Isolate the source of the noise. Remove the suspect engine accessory. Inspect the suspect engine accessory. Repair the engine accessory and/or replace the engine accessory, if necessary.

Valve Train Components Remove the valve mechanism cover. Check the following items for damage: camshaft, valve rotocoil, valve springs, camshaft followers, rocker shaft, bridges and injectors. Thoroughly clean the valve train components. If the camshaft is being replaced, also replace the valve lifters. Ensure that all of the valves move freely. Replace any damaged parts.

Pistons Inspect the pistons for damage and wear. Replace any damaged parts.

Crankshaft Inspect the crankshaft and the related components. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position. Look for worn thrust plates and wear on the crankshaft. Check the counterweight bolts. Replace any damaged parts.

Gear Train Inspect the condition of the gear train. Replace any damaged parts.

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Inspect the flywheel and the flywheel bolts.

Inspect the engine oil filters for nonferrous material. Flaking of nonferrous material could indicate worn gear train bearings.

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Tue Jul 14 16:38:41 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i05358944

Engine Misfires, Runs Rough or Is Unstable SMCS - 1000-035

Probable Causes • Poor fuel quality

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• Air in fuel

• Low fuel pressure

• Restriction in the fuel return line

• Fuel leakage from fuel injection line

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• Incorrect fuel setting

• Incorrect fuel injection timing • Incorrect valve setting

• Internal engine problem

Recommended Repairs Poor Fuel Quality

Ensure that there is good, clean fuel in the tank. When possible, interview the operator in order to determine if fuel quality is in question. Replace the fuel in the fuel tank with good, clean fuel if necessary. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test".

Air in the Fuel Check for air in the fuel system. Refer to Testing and Adjusting, "Air In Fuel".

Low Fuel Pressure Replace the primary fuel filter and the secondary fuel filter. Check the fuel lines for blockage or damage.

Fuel Leakage From Fuel Injection Line Check the fuel injection lines for leakage. If the fuel injection line nuts are loose, refer to the Disassembly and Assembly Manual tighten to the torque that is specified.

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Incorrect Fuel Setting

The fuel setting procedure can be performed with the governor and fuel injection pump on the engine.

Incorrect Fuel Injection Timing

Check Fuel Injection Timing. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for details.

Incorrect Valve Setting

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Check valve adjustment.

Internal Engine Problem

Check for signs of damaged valves, damaged cylinder head gasket, etc.

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Tue Jul 14 16:38:54 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i05320708

Engine Speed - Test SMCS - 1907-038; 1915-038

Specification

For the 303.5E, 304E, 305E, and 305.5E, refer to Testing and Adjusting, "Engine Performance - Test - Engine Speed" in the Hydraulic System manual for the low idle and high idle specifications.

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For the 901C, 902C, and 903C, refer to Testing and Adjusting, "Hydrostatic System - Test and Adjust" in the Power Train manual for the low idle and high idle specifications.

Required Tools

Table 1

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Required Tools

Part Number

Description

Qty

1U-6602

Photo-Tachometer

1

Engine Preparation

1. Ensure that the engine is level.

2. Stop the engine.

3. Install a piece of reflective tape on the fan or a pulley on the engine.

Test Procedure 1. Start the engine.

2. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).

3. Read the engine speed display (rpm) on the photo-tachometer. Refer to "Specification" for the specifications for engine speed at the desired engine operation.

Copyright 1993 - 2020 Caterpillar Inc.

Tue Jul 14 16:41:28 UTC+0530 2020

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Engine Top Speed Is Not Obtained SMCS - 1915-035

Probable Causes • Air inlet and exhaust system

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• Fuel supply

• Cylinder performance • Accessory equipment

Recommended Actions

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Air Inlet and Exhaust System

1. Check the air filter restriction indicator. Clean plugged air filters or replace plugged air filters.

Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting.

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the engine has been run out of fuel, it will be necessary to purge the air from the fuel system. Refer to Operation and Maintenance Manual.

2. Check the fuel lines for the following problems: restrictions, collapsed lines, pinched lines and loose connections. If problems are found with the fuel lines, repair the lines and/or replace the lines.

3. Check the fuel tank for foreign objects which may block the fuel supply.

4. Check the fuel filters.

5. Ensure that there is clean fuel in the fuel tank. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test". When possible interview the operator in order to determine if the fuel quality is questionable. Try to determine if this is started soon after refueling. Replace the fuel in the fuel tank with good, clean fuel if necessary.

6. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.

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Cylinder Performance

1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing and Adjusting for the procedure.

2. Possible causes of low compression are shown in the following list: Faulty piston Faulty piston rings

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Worn cylinder bores Worn valves

Faulty cylinder head gasket Damaged cylinder head

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3. Perform all necessary repairs. Ensure that the repairs have eliminated the problem.

Accessory Equipment

Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Tue Jul 14 16:39:09 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i04695898

Engine Vibration Is Excessive SMCS - 1000-035

Probable Causes • Vibration damper

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• Engine supports

• Driven equipment

• Engine misfiring and/or running rough

Recommended Actions

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Engine Supports

Inspect the mounts and the brackets while you run the engine through the speed range. Look for mounts and brackets that are loose and/or broken. Tighten all of the mounting bolts. Install new components, if necessary.

Driven Equipment

Check the alignment and the balance of any driven equipment.

Engine Misfiring or Running Rough Refer to the symptom Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".

Copyright 1993 - 2020 Caterpillar Inc.

Tue Jul 14 16:39:25 UTC+0530 2020

All Rights Reserved.

Private Network For SIS Licensees.

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

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Exhaust Has Excessive White Smoke SMCS - 1088-035; 1250-035

Note: Some white smoke may be present during cold start-up conditions when the engine is operating normally. If the white smoke persists, there may be a problem.

Probable Causes

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• Starting aids • Fuel supply • Cooling system • Unit injectors

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• Component wear

Recommended Actions Starting Aids (If Applicable)

1. If a jacket water heater is installed on your application, check for proper operation of the circuit.

Repair the circuit for the jacket water heater, if necessary.

Fuel Supply

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

Do not loosen any high pressure fuel lines when the engine is running.

The high pressure in the fuel lines can cause personal injury or death.

Wait 60 seconds after the engine has stopped to allow pressure to purge before any service or repair is performed on the engine fuel lines.

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1. Check the fuel pressure during engine cranking. Check the filtered fuel pressure. If the fuel pressure is low, replace the fuel filters. Refer to Systems Operation/Testing and Adjusting, "Fuel System Pressure - Test".

2. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.

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Cooling System

Check for an internal coolant leak into a cylinder and/or the exhaust. Refer to Systems Operation/Testing and Adjusting for information on inspecting the cooling system.

Ensure that the temperature readings for the sensor are reasonable for the conditions that are present.

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Component Wear

1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing and Adjusting.

2. Possible causes of low compression are shown in the following list: Faulty piston

Faulty piston rings Worn cylinder bores Worn valves Faulty cylinder head gasket

Damaged cylinder head Copyright 1993 - 2020 Caterpillar Inc.

Tue Jul 14 16:39:39 UTC+0530 2020

All Rights Reserved.

Private Network For SIS Licensees.

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s

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  Product: COMPACT WHEEL LOADER Model: 901C COMPACT WHEEL LOADER W4T Configuration: 901C Compact Wheel Loader W4T00001-UP (MACHINE) POWERED BY C1.8 Engine

Troubleshooting C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines Media Number -KENR6757-10

Publication Date -01/08/2015

Date Updated -02/06/2016

e l p i04695909

Exhaust System Contains Oil SMCS - 1050-035; 1348-035

Probable Causes • Worn valve guide seals or faulty valve guide seals

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• Worn valve guides • Worn piston rings

• Scored cylinder liners or worn cylinder liners

Recommended Actions

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Worn Valve Guide Seals or Faulty Valve Guide Seals Inspect the valve guide seals for wear and for damage. Replace the valve guide seals, if necessary.

Worn Valve Guides

Inspect the valve guides for wear. Refer to the Specification manual for the maximum permissible wear of the valve guides. If necessary, recondition the cylinder head.

Worn Piston Rings Piston rings that have excessive wear can cause too much pressure in the crankcase. The additional pressure in the crankcase will cause more than the normal amount of crankcase blowby from the

crankcase breather. Refer to Testing and Adjusting, "Compression - Test" for more information.

Inspect piston rings and install new parts, as required.

Copyright 1993 - 2020 Caterpillar Inc.

Tue Jul 14 16:39:53 UTC+0530 2020

All Rights Reserved.

Private Network For SIS Licensees.

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

Download Link