Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Alternator - Remove and Install - 55 Amp Alternator
SMCS - 1405-010
Removal Procedure
Start By:
Date Updated -30/06/2016
i02601956
a. Remove the V-Belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
1. Turn the battery disconnect switch to the OFFposition.
2. Make temporary identification markson the connections of the harness assembly.
Illustration 1 g01308282
Typicalexample
3. Disconnect the harness assembly (not shown) from alternator (5).
4. Remove bolt (2) and washer (3) from alternator (5).
5. Remove fasteners (6) and (7) and remove alternator (5) from the mounting bracket.
6. If necessary, remove bolt (2) and remove adjusting link (4).
Installation Procedure
Illustration 2 g01308282
Typicalexample
1. If necessary, install adjusting link (4) and install bolt (1) finger tight.
2. Position alternator (5) on the mounting bracket.
3. Install fasteners (6) and (7) finger tight.
4. Install bolt (2) and washer (3) finger tight.
5. Install the V-Belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Note: Ensure that the alternator pulley isin alignment with the crankshaft pulley. Ensure that all fasteners are tightened.
6. Connect the harness assembly (not shown) to the alternator.
7. Turn the battery disconnect switch to the ON position.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
i02601962
Alternator - Remove and Install - 65 Amp and 85 Amp Alternators
SMCS - 1405-010
Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
1. Turn the battery disconnect switch to the OFFposition.
2. Make temporary identification markson the connections of the harness assembly.
Illustration 1 g01308285
Typicalexample
3. Disconnect the harness assembly (not shown) from alternator (5).
4. Remove bolt (4) and washer (3) from alternator (5).
5. Remove washer (7) and nut (6). Remove bolt (8) and alternator (5) from the mounting bracket.
6. If necessary, remove bolt (1) and remove adjusting link (2).
Installation Procedure
Illustration 2 g01308285
Typicalexample
1. If necessary, install adjusting link (2) and install bolt (1) finger tight.
2. Position alternator (5) on the mounting bracket.
3. Install bolt (8), washer (7) and nut (6) finger tight.
4. Install bolt (4) and washer (3) finger tight.
5. Install the V-Belt. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Note: Ensure that the alternator pulley isin alignment with the crankshaft pulley. Ensure that all fasteners are tightened.
6. Connect the harness assembly (not shown) to the alternator.
7. Turn the battery disconnect switch to the ON position.
Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Jan 19 21:29:41 UTC+0530 2021
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Bearing Clearance - Check
SMCS - 1203-535; 1219-535
Measurement Procedure
Table 1 Required Tools
(Green)
Gauge (Red)
Date -01/06/2015
Updated -30/06/2016
i02237832
Gauge (Blue)
to 0.229 mm (0.004 to 0.009 inch)
Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)
Contaminants may cause rapid wear andshortened component life.
Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. Thisisbecause of the possibility of obtaining inaccurate results 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).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be very 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.
• The crankshaft must be free of oil at the contact pointsof 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 g00953605
TypicalExample
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 partsof Tooling (A) are not the same width. Measure the major width in order to ensure that the partsare within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and SpecificationsManual, "Main Bearing Journal" for the correct clearances.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
i02601967
Camshaft - Assemble
SMCS - 1210-016
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
1. Ensure that all components of the camshaft assembly are clean and free from damage.
Illustration 1 g01326129
Typicalexample
2. Lubricate the nose of camshaft (1) with clean engine oil. Use a suitable press to install bearing (3) to the camshaft.
Note: Ensure that the bearing isinstalled in the correct orientation. The camshaft bearing should be pressed squarely onto the camshaft or damage to the bearing may occur. Do not press on the outer race of the bearing.
3. Install spacer (4) and woodruff key (2) to camshaft (1).
4. Align gear (5) with woodruff key (2). Use a suitable press to install the gear to the nose of camshaft (1).
Note: The gear should be positioned on a suitable support in order to prevent damage to the governor flyweights during installation.
End By:
a. Install the camshaft assembly. Refer to Disassembly and Assembly, "Camshaft - Install".
1993 - 2021 Caterpillar Inc.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Camshaft - Disassemble
SMCS - 1210-015
Disassembly Procedure
Table 1 Required Tools
Publication Date -01/06/2015
Date Updated -30/06/2016
i02601970
Start By:
a. Remove the camshaft assembly. Refer to Disassembly and Assembly, "Camshaft - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
Illustration 1 g01326129
Typicalexample
1. Use Tooling (A) to remove gear (5) from camshaft (1).
Note: The gear should be positioned on a suitable support in order to prevent damage to the governor flyweights during disassembly.
2. Remove spacer (4) and woodruff key (2) from camshaft (1).
3. Use Tooling (A) to remove bearing (3) from camshaft (1).
Note: Identify the orientation of the bearing for installation.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Camshaft - Install
SMCS - 1210-012
Installation Procedure
Publication Date -01/06/2015
Date Updated -30/06/2016
i06721482
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
1. Ensure that the assembly of the camshaft is clean and free from damage.
2. Lubricate the bearings of the camshaft with clean engine oil.
Illustration 1 g01311416
Typicalexample
Illustration 2 g01311407
Typicalexample
3. Carefully install camshaft assembly (8) into the cylinder block. Ensure that timing marks(X) are aligned on the following gears:
Crankshaft gear (7)
Camshaft gear (4)
Idler gear (6)
Note: Do not damage the lobes of the camshaft or the camshaft bearings.
Illustration 3 g01311411
Typicalexample
4. Place camshaft retainer (5) in position. Align the holes in the retainer with the holes in the cylinder block.
5. Rotate camshaft gear (4) to align the accesshole in the camshaft gear with the hole for fastener (2).
Install bolt (2) and tighten to a torque of 10 N·m (89 lb in). Rotate camshaft gear (4) to align the access hole in the camshaft gear with the hole for bolt (1). Install bolt (1) and tighten to a torque of 10 N·m (89 lb in).
6. Install slider (3) to camshaft gear (4).
7. If the engine is equipped with a mechanical fuel transfer pump, install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Remove and Install".
End By:
a. Install the lifters. Refer to Disassembly and Assembly, "Lifter Group- Remove and Install".
b. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". Copyright 1993 - 2021 Caterpillar Inc.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
i06721478
Camshaft - Remove
SMCS - 1210-011
Removal Procedure
Start By:
a. Remove the lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".
b. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
NOTICE
Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, testing, adjusting and repair of the product. Be preparedto 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. If the engine is equipped with a mechanical fuel transfer pump, remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Remove and Install".
1 g01311407 Typicalexample
Illustration 2 g01311411
Typicalexample
2. Remove slider (3) from camshaft gear (4).
3. Rotate camshaft gear (4) to align the accesshole in the camshaft gear with fastener (2).
Remove bolt (2). Rotate camshaft gear (4) to align the access hole in the camshaft gear with bolt (1). Remove bolt (1).
4. Remove camshaft retainer (5).
5. Rotate the crankshaft until timing marks (X) are aligned on the following gears:
Crankshaft gear (7)
Camshaft gear (4)
Idler gear (6)
Illustration 3 g01311416
Typicalexample
6. Carefully remove camshaft assembly (8) from the cylinder block.
Note: Ensure that the lobes of the camshaft and the camshaft bearings are not damaged.
Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 19 21:24:58 UTC+0530 2021
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
Connecting Rod Bearings - Install - Connecting rods in position
SMCS - 1219-012
Installation Procedure NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
i06721485
1. Inspect the pins of the crankshaft for damage. If the crankshaft isdamaged, replace the crankshaft or recondition the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove" and Disassembly and Assembly, "Crankshaft - Install". Ensure that the connecting rod bearings are clean and free from wear or damage. If necessary, replace the connecting rod bearings.
Illustration 1 g01317759
Typicalexample
2. Clean the bearing surface of connecting rod (1) and connecting rod cap (5). Ensure that number (X) on connecting rod cap (5) alignswith number (X) on connecting rod (1).
3. Install upper connecting rod bearing (3) to connecting rod (1). Lubricate the bearing surface of the connecting rod bearing with clean engine oil.
4. Carefully pull connecting rod (1) against the crankshaft pin.
Note: Use tape or rubber tubing on connecting rod bolts (2) to protect the crankshaft journals. The sharp edges of the connecting rod bolts could damage the crankshaft journals.
5. Clean the connecting rod cap. Install lower connecting rod bearing (4) to connecting rod cap (5).
6. Lubricate the pin of the crankshaft and lubricate lower connecting rod bearing (3) with clean engine oil.
When the connecting rod caps are installed, ensure that the identification marks are aligned.
7. Install connecting rod cap (5).
8. Install nuts(4). Tighten nuts to a torque of 52 N·m (38 lb ft).
9. Ensure that the installed connecting rod assembly hastactile side play. Carefully rotate the crankshaft to ensure that there is no binding.
Note: If all connecting rod bearings require replacement on a four cylinder engine, the procedure can be carried out on two cylindersat 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 cylindersto another pair of cylinders. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove" for more information.
End By:
a. Install the suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
1993 - 2021 Caterpillar Inc.
Rights Reserved.
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
i02601978
Connecting Rod Bearings - Remove - Connecting rods in position
SMCS - 1219-011
Removal Procedure
Start By:
a. Remove the suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
Note: If all connecting rod bearings require replacement on a four cylinder engine, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairsof cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the connecting rodbearingsare installed before changing from one pair of cylinders to another pair of cylinders.. Refer to Disassembly and Assembly, "Connecting Rod Bearings- Install".
Illustration 1 g01317759
Typicalexample
Note: The connecting rod and the connecting rod cap should have matching numbers at position (X). If necessary, make a temporary mark on connecting rod (1) and on connecting rod cap (5).
1. Rotate the crankshaft until the piston isat the bottom center position. Remove nuts (6) and remove connecting rod cap (5) from connecting rod (1).
2. Remove lower connecting rod bearing (4) from connecting rod cap (5).
3. Carefully push connecting rod (1) into the cylinder bore. Remove upper connecting rod bearing (3) from the connecting rod.
Note: Use tape or rubber tubing on connecting rod bolts (2) in order to protect the crankshaft journals. The sharp edgesof the connecting rod bolts could damage the crankshaft journals.
Tue Jan 19 21:27:03 UTC+0530 2021
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Coolant Temperature Switch - Remove and Install
SMCS - 1906-010
Removal Procedure
Date Updated -30/06/2016
i02873606
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
NOTICE
Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, testing, adjusting and repair of the product. Be preparedto 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 into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Drain"for more information.
Illustration 1 g01326627
Typicalexample
2. Disconnect the harness assembly (not shown) from coolant temperature switch (2).
3. Remove coolant temperature switch (2) from water temperature regulator housing (1).
Installation Procedure
Table 1
Required Tools
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
1. Inspect the coolant temperature switch for damage and correct operation. Refer to Systems Operation, Testing and Adjusting, "Coolant Temperature Switch - Test" for more information. If necessary, replace the coolant temperature switch.
Illustration 2 g01326627
Typicalexample
2. Install coolant temperature switch (2) to water temperature regulator housing (1). Use a deep socket to tighten the coolant temperature switch to a torque of 27 N·m (20 lb ft).
Note: If a used coolant temperature switch is installed, apply a thin layer of Tooling (A) to the threads of the coolant temperature switch.
3. Connect the harness assembly (not shown) to coolant temperature switch (2).
4. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for more information. Copyright 1993 - 2021 Caterpillar Inc.
Network For SIS Licensees. Tue Jan 19 21:28:24 UTC+0530 2021
Product: SKID STEER LOADER
Model: 216B SKID STEER LOADER RLL04537
Configuration: 216B 226B 232B 242B Skid Steer Loader RLL00001-06799 (MACHINE) POWERED BY 3024C Engine
Disassembly and Assembly
C1.5 and C2.2 Engines for Caterpillar Built Machines
Media Number -KENR6948-04
Publication Date -01/06/2015
Date Updated -30/06/2016
Crankcase Breather - Remove and Install - Naturally Aspirated Engines
SMCS - 1317-010
Removal Procedure
i06720293
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
NOTICE
Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, testing, adjusting and repair of the product. Be preparedto 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.
The three cylinder and the four cylinder engineshave different crankcase breathers. The removal procedure issimilar for all models.
Illustration 1 g01307795
Typicalexample
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be releasedwhen coversare removed.
Be prepared to holdspring loaded covers as the bolts are loosened.
1. Remove bolts (1) and remove the assembly of cover (2), spring (3) and diaphragm (4). Note the orientation of cover (2).
2. Remove spring (3) and diaphragm (4) from cover (2).
3. If necessary, followSteps3.a through 3.c to remove the gauze for the breather.
a. Remove valve mechanism cover (7). Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
b. Remove screws (8) and carefully remove plate (9).
c. Remove gauze (6) from valve mechanism cover (7).
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite 594B 247-5377 Torque Wrench 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear andshortened component life.
NOTICE
Make sure that the componentsof the breather assembly are installed correctly. Engine damage may occur if the breather assembly isnot working properly.
The three cylinder and the four cylinder engineshave different crankcase breathers. The installation procedure issimilar for all models.
Illustration 2 g01307795
Typicalexample
1. Clean all parts and inspect all parts. Replace any parts that are worn or damaged. Ensure that the cavity for the breather in the valve mechanism cover is clean. Ensure that vent hole (5) and the vent hole in cover (2) are free from restriction.
2. If necessary, followSteps2.a through 2.e to install the gauze for the breather.
a. Install gauze (6) to valve mechanism cover (7).
b. Apply a bead of Tooling (A) to the mating surface of the plate on valve mechanism cover (7).
c. Position plate (9) on valve mechanism cover (7) and install screws (8).
d. Tighten screws (8) to a torque of 1.5 N·m (13 lb in).
e. Install valve mechanism cover (7). Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommendedtooling to release the spring force.
3. Install diaphragm (4) and spring (3) to cover (2).
4. Position the assembly of cover (2), spring (3) and diaphragm (4) onto valve mechanism cover (7).
Note: Ensure the correct orientation of the cover.
5. Install bolts (1). Use Tooling (B) to tighten boltsto a torque of 3 N·m (27 lb in).