902C2 Caterpillar Compact Wheel Loader Service Repair Manual

SERVICE REPAIR MANUAL 902C2 COMPACT WHEEL LOADER

Printed by:- quality-service-repair-manual.com

























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



























































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







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











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















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



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



















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







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



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



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



























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



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



  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06571093

Alternator - Remove and Install SMCS - 1405-010

Removal Procedure

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

1. Open the hood.

2. Turn the disconnect switch to the OFF position.

Illustration 1

g06027039

3. Remove bolt (1) and the washers. Remove panel (2).

Illustration 2

g06027050

4. Disconnect cable assembly (5). Disconnect harness assembly (6). Loosen bolt (3) and remove the belt from alternator (4). Remove bolt (3) and bolt (7). Remove alternator (4).

Installation Procedure

Illustration 3

g06027050

1. Install alternator (4). Install the washer and bolt (7) loosely. Install the washer and bolt (3) loosely.

2. Install the belt and adjust the belt to the proper tension. Refer to Operation and Maintenance Manual for the correct adjustment procedure. Tighten bolt (7) and bolt (3).

3. Connect harness assembly (6). Connect cable assembly (5).

Illustration 4

g06027039

4. Install cover (2). Install bolts (1).

5. Turn the disconnect switch to the ON position.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:05:08 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06510951

Alternator - Remove and Install SMCS - 1405-010

Removal Procedure 1. Turn the battery disconnect switch to the OFF Position.

2. Disconnect the negative battery cable.

Illustration 1

g06002994

3. Remove bolt (1), bolts (2), and bracket assembly (3).

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

Download Link

Illustration 2

g06010523

4. Disconnect harness assemblies (4) (not shown).

5. Remove bolt (6), belt (7), and alternator (5).

Illustration 3

g06010528

6. Remove nut (9) and pulley (8).

Installation Procedure 1. Install alternator (5) in the reverse order of removal. a. Tighten nut (9) to a torque of 58 N·m to 79 N·m (43 lb ft to 58 lb ft).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:04:53 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06512975

Boost Pressure Sensor - Remove and Install SMCS - 1917-010

Removal Procedure

Illustration 1

g06004294

1. Remove bolt (2) and boost pressure sensor (1).

Installation Procedure 1. Install boost pressure sensor (1) in the reverse order of removal. a. Tighten bolt (2) to a torque of 1 N·m to 2 N·m (9 lb in to 18 lb in).

Sat Jul 18 10:04:22 UTC+0530 2020

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06541348

Camshaft - Remove and Install SMCS - 1210-010

Removal Procedure Start By: a. Remove cylinder head.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1

g06014635

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

Illustration 2

g06014606

2. Remove lifters (1).

Illustration 3

g06014643

3. Remove bolts (2) and camshaft (3).

Installation Procedure 1. Install camshaft (3) in the reverse order of removal. a. Tighten bolts (2) to a torque of 24 N·m to 27 N·m (212 lb in to 239 lb in).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:01:11 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06547544

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

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Group

1

B

8B-7551

Puller Assembly

1

Start By: 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

g02721209

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

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. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:01:27 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06512802

Camshaft Position Sensor - Remove and Install SMCS - 1912-010

Removal Procedure

Illustration 1

g06004093

1. Disconnect harness assembly (1) (not shown).

2. Remove bolt (3), camshaft position sensor (2), and the O-ring seal.

Note: If camshaft position sensor (2) is dropped, do not reuse.

Installation Procedure 1. Install camshaft position sensor (2) in the reverse order of removal.

a. Tighten bolt (3) to a torque of 4 N·m to 5 N·m (35 lb in to 44 lb in).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:03:24 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06511883

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

Removal Procedure 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

g06003343

1. Disconnect harness assembly (2) (not shown).

2. Remove coolant temperature sensor (1).

Installation Procedure 1. Install coolant temperature sensor (1) in the reverse order of removal. a. Tighten coolant temperature sensor (1) to a torque of 16 N·m to 23 N·m (142 lb in to 204 lb in).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:03:54 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06544622

Crankshaft - Install SMCS - 1202-012

Installation Procedure 1. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft.

2. Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the threads for the bearing bolts in the cylinder block are clean and free from damage.

3. Clean the crankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers.

Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.

4. Ensure that all the lubrication passages are clean and free of debris.

Illustration 1

g06016885

5. Install crankshaft bearing. (7).

Illustration 2

g06016931

6. When you install the main bearing case assemblies, point the mark FLYWHEEL (Y) to the flywheel.

Illustration 3

g06016876

Illustration 4

g06045656

7. Install main bearings (6) and thrust bearings (5) Note: When you install thrust bearings (5) point the oil grooves externally.

Illustration 5

g06016479

8. Install main bearing case assemblies (4) and bolts (3). Tighten bolts (3) to a torque of 46 N·m to 50 N·m (34 lb ft to 37 lb ft).

Note: Install the main bearing case assemblies (4) in the initial positions. Since the diameters of the main bearing case assemblies are different, install them in the sequence of their marks on the gear case side.

Illustration 6

g06016404

Illustration 7

g06016439

9. Rotate crankshaft (2) and align the crankshaft journals with the reliefs (X) in the Cylinder Block. Use two people to install the crankshaft into the cylinder block. The weight of crankshaft (2) is approximately 24 kg (53 lb).

10. Tighten bolts (1) to a torque of 69 N·m to 73 N·m (51 lb ft to 54 lb ft).

11. Check the crankshaft end play, side clearance, and oil clearance. Refer to Specifications, "Crankshaft" for more information.

12. Check the piston height. Refer to Systems Operation, Testing and Adjusting, "Piston Height Inspect" for more information.

End By: a. Install pistons and connecting rods.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:02:55 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06543010

Crankshaft - Remove SMCS - 1202-011

Removal Procedure Start By: a. Remove pistons and connecting rods.

NOTICE If the crankshaft has been reground or replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head to inspect the height of the piston above the cylinder block.

Note: Before you disassemble, measure the side clearance of the crankshaft. Measure it when you reassemble.

Illustration 1

g06016404

1. Remove bolts (1).

Illustration 2

g06016439

2. Rotate crankshaft (2) and align the crankshaft journals with the reliefs (X) in the Cylinder Block. Use two people to pull the crankshaft out of the cylinder block. The weight of crankshaft (2) is approximately 24 kg (53 lb).

Illustration 3

g06016479

3. Remove bolts (3) and main bearing case assemblies (4).

Illustration 4

g06016876

4. Remove main bearings (6) and thrust bearings (5).

Illustration 5

g06016885

5. Remove crankshaft bearing (7).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 10:02:40 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06540618

Crankshaft Front Seal - Remove and Install SMCS - 1160-010

Removal Procedure Start By: a. Remove crankshaft pulley.

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

g02717555

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

Illustration 2

g02717557

2. Remove crankshaft front seal (3).

Installation Procedure 1. Install crankshaft front seal (3) in the reverse order of removal.

Note: The crankshaft front seal should be installed dry. Lubricate the inner rubber portion of the crankshaft front seal. a. Inspect the nose of the crankshaft for damage. Ensure that the crankshaft is clean and dry.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Sat Jul 18 09:59:21 UTC+0530 2020

  Product: COMPACT WHEEL LOADER Model: 902C2 COMPACT WHEEL LOADER YKT Configuration: 902C2 Compact Wheel Loader YKT00001-UP (MACHINE) POWERED BY C2.4 Engine

Disassembly and Assembly C2.4 Tier 4 Final Engines for Caterpillar Built Machines Media Number -UENR7319-01

Publication Date -01/07/2016

Date Updated -04/07/2016

i06541555

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

Removal Procedure Table 1 Required Tooling Tool

Part Number

Part Description

Qty

A

1P-2321

Puller Assembly

1

Start By: a. Remove idler gear.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Download Link