Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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 componentsto 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 harnessassembly (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).
4. Install cover (2). Install bolts(1).
5. Turn the disconnect switch to the ONposition.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Mon Jul 20 15:30:16 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
i06510951
Alternator - Remove and Install
SMCS - 1405-010
Removal Procedure
1. Turn the battery disconnect switch to the OFFPosition.
2. Disconnect the negative battery cable.
Illustration 1 g06002994
3. Remove bolt (1), bolts(2), and bracket assembly (3).
Illustration 2
g06010523
4. Disconnect harnessassemblies(4) (not shown).
5. Remove bolt (6), belt (7), and alternator (5).
Illustration 3
6. Remove nut (9) and pulley (8).
Installation
Procedure
g06010528
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. Mon Jul 20 15:30:01 UTC+0530 2020
This is the sample of the manual click on the download link for complete manual
DOWNLOAD LINK
Compact Wheel Loader MW800001-UP(MACHINE) POWEREDBY C2.4 Engi
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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).
Mon Jul 20 15:27:10 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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
2. Remove lifters(1).
g06014606
Illustration 3
3. Remove bolts (2) and camshaft (3).
Installation Procedure
g06014643
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).
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
i06547544
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Table 1
Required Tools
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 fluidsare 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 regulationsand mandates.
Illustration 1
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
2. Remove plate (3) from camshaft (2).
3. If necessary, remove the key from the nose of the camshaft.
Installation Procedure
g02721209
g02721212
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.
Mon Jul 20 15:21:13 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
Camshaft Position Sensor - Remove and Install
SMCS - 1912-010
Removal Procedure
Illustration 1
g06004093
1. Disconnect harnessassembly (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.
i06512802
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.
Mon Jul 20 15:26:16 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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 fluidsare 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 regulationsand mandates.
i06511883
Illustration 1 g06003343
1. Disconnect harnessassembly (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.
Mon Jul 20 15:26:43 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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 bearingsand the thrust washers.
Note: If the crankshaft bearings are replaced, check whether oversize bearingswere 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
5. Install crankshaft bearing. (7).
g06016885
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 groovesexternally.
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 markson the gear case side.
Illustration 6
g06016404
Illustration 7
g06016439
9. Rotate crankshaft (2) and align the crankshaft journalswith the reliefs(X) in the Cylinder Block. Use two people to install the crankshaft into the cylinder block. The weight of crankshaft (2) isapproximately 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 HeightInspect" for more information.
End By:
a. Install pistons and connecting rods.
Copyright 1993 - 2020 Caterpillar Inc.
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
i06543010
Crankshaft - Remove
SMCS - 1202-011
Removal Procedure
Start By:
a. Remove pistonsand connecting rods.
NOTICE
If the crankshaft hasbeenreground 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
1. Remove bolts (1).
Illustration 2
g06016439
2. Rotate crankshaft (2) and align the crankshaft journalswith 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
g06016404
3. Remove bolts (3) and main bearing case assemblies (4).
Illustration 4
g06016876
4. Remove main bearings (6) and thrust bearings(5).
Illustration 5
5. Remove crankshaft bearing (7).
g06016885
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Jul 20 15:25:34 UTC+0530 2020
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
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 fluidsare 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 regulationsand mandates.
i06540618
Illustration 1
1. Remove key (1) and sleeve (2) from the crankshaft.
Illustration 2
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.
g02717555
g02717557
Product: COMPACT WHEEL LOADER
Model: 903C2 COMPACT WHEEL LOADER MW8
Configuration: 903C2 Compact Wheel Loader MW800001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
Crankshaft Gear - Remove and Install
SMCS - 1204-010-GE
Removal Procedure
Table 1
Required Tooling
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.
i06541555
This is the sample of the manual click on the download link for complete manual
